Vertical sequencer for product order fulfillment

ABSTRACT

A product order fulfillment system including a multi-level transport system and a lifting transport system. Each level of the multi-level transport system having a corresponding independent asynchronous level transport system separate and distinct from the asynchronous level transport system corresponding to each other level of the multi-level transport system. Each independent lift axis of the lifting transport system being configured to independently hold at least one case and being communicably coupled to each asynchronous level transport system so as to provide for exchange of the at least one case between each asynchronous level transport system and each independent lift axis. Each independent lift axis is communicably coupled to each other independent lift axis of the more than one lift axis and forms a common output of mixed cases so as to create an ordered sequence of mixed cases in accordance to a predetermined case out ordered sequence.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/444,592, filed Jun. 18, 2019, (now U.S. Pat. No. 10,947,060), whichis a non-provisional of and claims the benefit of U.S. ProvisionalPatent Application No. 62/689,938, filed Jun. 26, 2018, the disclosuresof which are incorporated herein by reference in their entireties.

BACKGROUND 1. Field

The exemplary embodiments generally relate to storage and retrievalsystem and, more particularly, to vertical sequencing of items in thestorage and retrieval system.

2. Brief Description of Related Developments

Generally, in storage and retrieval systems case units or items arepicked and transported to an outbound packaging cell (e.g., a humanpicking cell and/or an automated palletizer). These picked case unitsare sequenced according to a product order for placement on a pallet orother shipping container.

The case units output from the multilevel storage and retrieval systemsare transferred to a packing station where the case units are placed onpallets for shipping. Generally the pallets include case units ofsimilar size and shape so that stable case levels, sometimes withpaperboard sheets disposed between the levels, are formed on thepallets. In some instances each level of tier of the pallet isseparately formed and then placed on the pallet to form stacked tiers.Mixed pallets are also possible. Generally when forming a pallet layercases are placed in a buffer station or other location at thepalletizing station so that the dimensions of the case are measured. Acomputer or other processor determines an arrangement (e.g., sequence)of the cases based on the dimensions and instructs a robot to pick thecases for placement in the pallet layer. In other instances, thesequencing of the items is performed by automation or humans picking theitems from storage shelves where the items are transferred from storageto outbound conveyors in a sequenced order. This sequencing generallyoccurs during horizontal transfer of the items and at rates that aregenerally slower than rates at which the items can be palletized orpacked into other shipping containers.

It would be advantageous to sort case units for placement on a palletduring vertical transport of the case units out of the storage andretrieval system storage structure to increase throughput of the storageand retrieval system.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodiment areexplained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1A is a schematic illustration of an automated storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIGS. 1B and 1C are schematic illustrations of portions of the automatedstorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 1D is a schematic illustration of a mixed pallet load formed by theautomated storage and retrieval system in accordance with aspects of thedisclosed embodiment;

FIG. 2A is a schematic illustration of a transport vehicle in accordancewith aspects of the disclosed embodiment;

FIG. 2B is a schematic illustration of a transport vehicle in accordancewith aspects of the disclosed embodiment;

FIGS. 3 and 3A are schematic illustrations of portions of the storageand retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 4A is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIG. 4B is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIGS. 5A, 5B, 5C, and 5D are schematic illustrations of portions of thestorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIGS. 6A and 6B are schematic illustrations of portions of the storageand retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 7 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIG. 7A is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIG. 8 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIGS. 8A, 8B, and 8C are schematic illustrations of a portion of thestorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 9 is a flow diagram of a vertical case unit sequencing inaccordance with aspects of the disclosed embodiment;

FIG. 10 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIGS. 10A, 10B, and 10C are schematic illustrations of a portion of thestorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 11 is a flow diagram of a vertical case unit sequencing inaccordance with aspects of the disclosed embodiment;

FIG. 12 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIGS. 12A, 12B, and 12C are schematic illustrations of a portion of thestorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 13 is a flow diagram of a vertical case unit sequencing inaccordance with aspects of the disclosed embodiment;

FIG. 14 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIG. 15 is a flow diagram of an exemplary product order fulfillmentmethod in accordance with aspects of the disclosed embodiment; and

FIG. 16 a flow diagram of an exemplary product order fulfillment methodin accordance with aspects of the disclosed embodiment.

DETAILED DESCRIPTION

Although the aspects of the disclosed embodiment will be described withreference to the drawings, it should be understood that the aspects ofthe disclosed embodiment can be embodied in many forms. In addition, anysuitable size, shape or type of elements or materials could be used.

FIG. 1A is a schematic illustration of an automated storage andretrieval system 100 including a multi-level transport system 190 inaccordance with aspects of the disclosed embodiment. Each level 130L ofthe multi-level transport system 190 includes an asynchronous leveltransport system 191 that is separate and distinct from the asynchronouslevel transport system 191 at each other level 130L of the multi-leveltransport system 190. The multi-level transport system 190 is coupled toand feeds an infeed order sequence 173 of mixed cases to a liftingtransport system 500 that connects each asynchronous level transportsystem 191 to a case output having a predetermined mixed case out ordersequence. As shown, the lifting transport system 500 (see also FIG. 5A)may have separate inbound and outbound transport sections 500A, 500B.The outbound transport section 500B has one or more lift transport cells150CEL (see also FIG. 5A), each or at least one of which has more thanone independent lift axis 150X1-150Xn (FIG. 5A) coupled to each otherand controlled in a cooperative manner as will be described herein. Eachof the independent lift axis 150X1-150Xn of the lift transport cell150CEL (also referred to herein as “cell” 150CEL) independently feedscases, from any of the asynchronous level transport systems 191, througha common output 300 of the cell 150CEL that creates an ordered sequenceof mixed cases 171 from the common output 300 in accordance with thepredetermined mixed case out order sequence. The output of a cell 150CELgenerates a predetermined case our order sequence of mixed cases 172 fora corresponding order fill station 160UT. In other aspects, the outputof the more than one cell are superposed or aggregated to generate thepredetermined case our order sequence of mixed cases 172 for the orderfill station 160UT. The inbound transport section 500A may be similar tothe outbound transport section 500B, or may have any suitable number ofindependent lift axes that may be coupled or uncoupled with respect toan inbound flow of cases to the storage structure 130.

The ordered sequence of mixed cases 171 from the more than oneindependent lift axis 150X1-150Xn, of the lifting transport system 500,is decoupled from the infeed order sequence 173 of each asynchronouslevel transport system 191, and effects a resequencing of cases, alongthe more than one independent lift axis 150X1-150Xn, between infeed tothe more than one independent lift axis 150X1-150Nx and the output 300of the more than one independent lift axis 150X1-150Xn so that theoutput ordered sequence of cases 171 has a superior sequence orderrelative to the predetermined case out order sequence of mixed cases 172than the infeed order sequence 173 of cases at each level 130L; and sothat in one aspect, outfeed transport work, outputting cases through themulti-level transport system 190 and the lifting transport system 500 isoptimally distributed (e.g., in desired optimization strategies of oneor more transactions) over the levels 130L of the multi-level transportsystem 190.

While the aspects of the disclosed embodiment are described herein withrespect to the storage and retrieval system 100, it should be understoodthat the aspects of the disclosed embodiment are equally applicable toany suitable material handling center(s) including, but not limited to,warehouses, distribution centers, cross-docking facilities, orderfulfillment centers/facilities, packaging facilities, shippingfacilities, or other suitable facility or combination of facilities forperforming one or more functions of material or inventory handling. Inaccordance with aspects of the disclosed embodiment the automatedstorage and retrieval system 100 may operate in a retail distributioncenter or warehouse to, for example, fulfill orders received from retailstores for case units (for simplicity and ease of explanation the term“case unit(s)” or the synonymous term “case” is generally used hereinfor referring to both individual case units and pickfaces, where apickface is formed of multiple case units that are moved as a unit) suchas those described in U.S. patent application Ser. No. 13/326,674 filedon Dec. 15, 2011, the disclosure of which is incorporated by referenceherein in its entirety. For example, the case units are cases or unitsof goods not stored in trays, on totes or on pallets (e.g. uncontained).In other examples, the case units are cases or units of goods that arecontained in any suitable manner such as in trays, on totes or onpallets. In still other examples, the case units are a combination ofuncontained and contained items. It is noted that the case units, forexample, include cased units of goods (e.g. case of soup cans, boxes ofcereal, etc.), individual goods that are adapted to be taken off of orplaced on a pallet, a product, a package, a box, a tote, a mailer, abucket and/or other types of containers. In accordance with the aspectsof the disclosed embodiment, shipping cases for case units (e.g.cartons, barrels, boxes, crates, jugs, or any other suitable device forholding case units) may have variable sizes and may be used to hold caseunits in shipping and may be configured so they are capable of beingpalletized for shipping. It is noted that when, for example, bundles orpallets of case units arrive at the storage and retrieval system thecontent of each pallet may be uniform (e.g. each pallet holds apredetermined number of the same item—one pallet holds soup and anotherpallet holds cereal) and as pallets leave the storage and retrievalsystem the pallets may contain any suitable number and combination ofdifferent case units (e.g. a mixed pallet where each mixed pallet holdsdifferent types of case units—a pallet holds a combination of soup andcereal) that are provided to, for example the palletizer in a sortedarrangement for forming the mixed pallet. In the embodiments the storageand retrieval system described herein may be applied to any environmentin which case units are stored and retrieved.

Also referring to FIG. 1D, it is noted that when, for example, incomingbundles or pallets (e.g. from manufacturers or suppliers of case unitsarrive at the storage and retrieval system for replenishment of theautomated storage and retrieval system 100, the content of each palletmay be uniform (e.g. each pallet holds a predetermined number of thesame item—one pallet holds soup and another pallet holds cereal). As maybe realized, the cases of such pallet load may be substantially similaror in other words, homogenous cases (e.g. similar dimensions), and mayhave the same SKU (otherwise, as noted before the pallets may be“rainbow” pallets having layers formed of homogeneous cases). As palletsPAL leave the storage and retrieval system 100, with cases fillingreplenishment orders, the pallets PAL may contain any suitable numberand combination of different case units CU (e.g. each pallet may holddifferent types of case units—a pallet holds a combination of cannedsoup, cereal, beverage packs, cosmetics and household cleaners). Thecases combined onto a single pallet may have different dimensions and/ordifferent SKU's. In one aspect of the exemplary embodiment, the storageand retrieval system 100 may be configured to generally include anin-feed section, a multi-level transport system 190, and an output andresequencing section 199 (where, in one aspect, storage of items isoptional) as will be described in greater detail below. As may berealized, in one aspect of the disclosed embodiment the system 100operating, for example, as a retail distribution center may serve toreceive uniform pallet loads of cases, breakdown the pallet goods ordisassociate the cases from the uniform pallet loads into independentcase units handled individually by the system, retrieve and sort thedifferent cases sought by each order into corresponding groups, andtransport and assemble the corresponding groups of cases into what maybe referred to as mixed case pallet loads MPL. The in-feed section maygenerally be capable of resolving the uniform pallet loads to individualcases, and transporting the cases via suitable transport, for input tothe storage and resequencing section 199. In other aspects the outputsection assembles the appropriate group of ordered case units, that maybe different in SKU, dimensions, etc. into bags, totes or other suitablecontainers according to the predetermined order sequence of picked itemsat the operator station 160EP (such as to fill a customer order).

As may also be realized, as illustrated in FIG. 13, in one aspect of thedisclosed embodiment the system 100 operating for example as a retaildistribution center may serve to receive uniform pallet loads of cases,breakdown the pallet goods or disassociate the cases from the uniformpallet loads into independent case units handled individually by thesystem, retrieve and sort the different cases sought by each order intocorresponding groups, and transport and sequence the correspondinggroups of cases (in the manner described herein) at an operator station160EP where items are picked from the different case units CU, and/orthe different case units CU themselves, are placed in one or morebag(s), tote(s) or other suitable container(s) TOT by an operator 1500,or any suitable automation, in a predetermined order sequence of pickeditems according to, for example, an order, fulfilling one or morecustomer orders, in which the case units CU are sequenced at theoperator station 160EP in accordance with the predetermined ordersequence, noting that the sequencing of the case units CU as describedherein effects the sequencing of the case units CU at the operatorstation 160EP.

Referring to FIGS. 1A and 5A, the output and resequencing section 199includes, at least a lifting transport system 500 (FIG. 5A) with morethan one independent lift axis 150X1-150Xn (see FIG. 5A, where in oneaspect each lift axis is a lift 150B, while in other aspects each liftaxis may be any suitable lifting device as described herein with respectto lifts 150) that are coupled or uncoupled so as to form a commoninfeed interface 555 frame 777 (see FIG. 7, e.g., so that the infeedinterface 555 frame 777 is common to each lift axis 150X1-150Xn) andcouple the multi-level transport system 190 to the output stations(s)160UT through a common output 300. Each of the lift axes 150X1-150Xn isconfigured to independently hold at least one case unit and reciprocatealong a vertical axis (i.e., the Z axis or lift travel axis) of the liftaxis independently raising and lowering the at least one case unit(singly or in groups, or in pickfaces) to provide lifting transport ofmixed cases between more than one level 130L of the multi-leveltransport system 190, as will be described in greater detail below.

In the exemplary embodiment, and referring to FIG. 1D, the output andresequencing section 199 generates the pallet load MPL in what may bereferred to as a structured architecture of mixed case stacks. Thestructured architecture of the pallet load MPL described herein isrepresentative and in other aspects the pallet load MPL may have anyother suitable configuration. For example, the structured architecturemay be any suitable predetermined configuration such as a truck bay loador other suitable container or load container envelope holding astructural load. The structured architecture of the pallet load MPL maybe characterized as having several flat case layers L121-L125, L12T, atleast one of which is formed of non-intersecting, free-standing andstable stacks of multiple mixed cases. The mixed case stacks of thegiven layer have substantially the same height, to form as may berealized substantially flat top and bottom surfaces of the given layer,and may be sufficient in number to cover the pallet area, or a desiredportion of the pallet area. Overlaying layer(s) may be orientated sothat corresponding cases of the layer(s) bridge between the stacks ofthe supporting layer. Thus, stabilizing the stacks and correspondinglythe interfacing layer(s) of the pallet load. In defining the pallet loadinto a structured layer architecture, the coupled 3-D pallet loadsolution is resolved into two parts that may be saved separately, avertical (1-D) part resolving the load into layers, and a horizontal(2-D) part of efficiently distributing stacks of equal height to fillout the pallet height of each layer. As will be described below, theoutput and resequencing section 199 outputs case units so that the twoparts of the 3-D pallet load solution are resolved. The predeterminedstructure of the mixed pallet load MPL defines an order of case units,whether the case units are a singular case unit pickface or a combinedcase unit pickface provided by the output and resequencing sections 199to a load construction system (which may be automated or manualloading). As may be realized, separate portions of the predeterminedstructure of the mixed pallet load MPL (e.g., a separate layer, or aportion of the layer) may each define the output case units desired forsequencing by the output and resequencing section(s) 199.

In accordance with aspects of the disclosed embodiment, referring againto FIG. 1A, the automated storage and retrieval system 100 includesinput stations 1601N (which include depalletizers 160PA and/or conveyors160CA for transporting items to lift modules 150A for entry intostorage) and output stations 160UT (which include palletizers 160PB,operator stations 160EP and/or conveyors 160CB for transporting caseunits from lift modules 150B for removal from storage), input and outputvertical lift modules 150A, 150B (generally referred to as lift modules150—it is noted that while input and output lift modules are shown, asingle lift module may be used to both input and remove case units fromthe storage structure), a storage structure 130, and a number ofautonomous rovers/vehicles or transport vehicles 110 (referred to hereinas “bots”). It is noted that the depalletizers 160PA may be configuredto remove case units from pallets so that the input station 1601N cantransport the items to the lift modules 150 for input into the storagestructure 130. The palletizers 160PB may be configured to place itemsremoved from the storage structure 130 on pallets PAL (FIG. 1D) forshipping.

The lift modules 150 and the respective lift axis (whether inbound oroutbound) may be shown as reciprocating lifts in the figures; however,in other aspects the lift modules 150 may be any suitable verticallyconfigured item handling device(s) such as, for example, an elevator(e.g., reciprocating lift) 150A1, 150B1, escalator 150A2, 150B2, angledconveyor belt 150A3, 150B3, unmanned aerial vehicle (e.g., a drone,quadcopter, multi-copter, etc.) 150A4, 150B4, and/or crane/hoist 150A5,150B5. As used herein the lift modules 150 (e.g., in the outbounddirection) may be referred to as the lifting transport system 500 thatdefines the output and resequencing section 199. In one aspect theoutput and resequencing section 199 is configured to pick one or morecases from one or more transfer deck levels (e.g., each transfer decklevel corresponding to a storage structure level 130L) and transport theone or more cases to a load fill section or cell (such as output station160UT) of the storage and retrieval system 100. The term load fillsection or load fill cell (used interchangeably herein, and generallyreferred to as a load fill) refers to either a pallet load fillsection/cell (such as for the creation of a mixed pallet load MPL) or anitemized load fill section/cell as described with respect to FIG. 14.

At least the storage structure 130 (including one or more of the pickingaisles 130A, storage spaces 130S and transfer deck 130B of eachdifferent storage structure level 130L) and bots 110 may be collectivelyreferred to herein as the multi-level transport system 190. Each level130L of the multi-level transport system 190 having a correspondingasynchronous level transport system 191 (which includes, e.g., the bots110, the picking aisles 130A, storage spaces 130S and transfer deck 130Bof the respective level 130L), of mixed cases, that is separate anddistinct from the level transport system 191 corresponding to each otherlevel 130L of the multi-level transport system 190. The asynchronouslevel transport system 190 defines an array of level asynchronoustransport axes X and Y (see e.g., FIGS. 2A and 2B—as described below),corresponding to the respective level 130L, and being configured to holdand asynchronously transport at least one case unit providing transportof mixed cases along the array of the level transport axes X and Y aswill be described below.

Also referring to, for example, FIGS. 1B, 1C and 3, the storagestructure 130 may include multiple storage rack modules RM, configuredin a high density three dimensional rack array RMA, that are accessibleby storage or deck levels 130L. As used herein the term “high densitythree dimensional rack array” refers to a storage array in which a totalnumber of deck levels that is less than a total number of rack levelswhere, for example, the three dimensional rack array RMA hasundeterministic open shelving distributed along picking aisles 130Awhere multiple stacked shelves 1210 are accessible from a common pickingaisle travel surface or picking aisle level (e.g. case units are placedat each picking aisle level within dynamically allocated storage spacesso that the vertical space/gap VG and horizontal space/gap G betweencase units is minimized at each picking aisle level, as described in forexample, U.S. Pat. No. 9,856,083 issued on Jan. 2, 2018, the disclosureof which is incorporated herein by reference in its entirety).

Referring to, for example, FIGS. 1A, 1B, 1C and 3, each storage level130L includes pickface storage/handoff spaces 130S (referred to hereinas storage spaces 130S) formed by the rack modules RM. The storagespaces 130S formed by the rack modules, in one aspect, include shelvesthat are disposed along storage or picking aisles 130A (that areconnected to the transfer deck 130B) which, e.g., extend linearlythrough the rack module array RMA and provide bot 110 access to thestorage spaces 130S and transfer deck(s) 130B. In other aspects, thestorage spaces 130S formed by the rack modules may include slots,receptacle, stalls, cribs, cordoned areas, hooks, racks, or othersuitable locations with a configuration that allows the bots to pick andplace case units to and from the storage spaces. In one aspect, theshelves of the rack modules RM are arranged as multi-level shelves thatare distributed along the picking aisles 130A. As may be realized thebots 110 travel on a respective storage level 130L along the pickingaisles 130A and the transfer deck 130B for transferring case unitsbetween any of the storage spaces 130S of the storage structure 130(e.g. on the level which the bot 110 is located) and any of the liftmodules 150 (e.g. each of the bots 110 has access to each storage space130S on a respective level and each lift module 150 on a respectivestorage level 130L). The transfer decks 130B are arranged at differentlevels (corresponding to each level 130L of the storage and retrievalsystem) that may be stacked one over the other or horizontally offset,such as having one transfer deck 130B at one end or side RMAE1 of thestorage rack array RMA or at several ends or sides RMAE1, RMAE2 of thestorage rack array RMA as described in, for example, U.S. patentapplication Ser. No. 13/326,674 filed on Dec. 15, 2011 the disclosure ofwhich is incorporated herein by reference in its entirety. In otheraspects, the storage structure may not have transfer decks on one ormore of the level 130L, where the picking aisles may extend so that thebots 110 have access to one or more lifts disposed on a side of thepicking aisle in a manner similar to that described in, for example,U.S. Pat. No. 8,974,168 issued on Mar. 10, 2015, the disclosure of whichis incorporated herein by reference in its entirety.

In one aspect of the disclosed embodiment, the transfer decks 130B aresubstantially open and configured for the undeterministic traversal ofbots 110 along multiple travel lanes (e.g. along an asynchronous Xtransport axis with respect to the bot frame of reference REFillustrated in FIGS. 2A and 2B) across and along the transfer decks130B. As may be realized, the transfer deck(s) 130B at each storagelevel 130L communicate with each of the picking aisles 130A on therespective storage level 130L. Bots 110 bi-directionally traversebetween the transfer deck(s) 130B and picking aisles 130A on eachrespective storage level 130L so as to travel along the picking aisles(e.g. along the asynchronous X transport axis with respect to the botframe of reference REF illustrated in FIGS. 2A and 2B) and access thestorage spaces 130S disposed in the rack shelves alongside each of thepicking aisles 130A (e.g. bots 110 may access, along an asynchronous Ytransport axis (with respect to the bot frame of reference REFillustrated in FIGS. 2A and 2B), storage spaces 130S distributed on bothsides of each aisle such that the bot 110 may have a different facingwhen traversing each picking aisle 130A, for example, referring to FIGS.2A and 2B, drive wheels 202 leading a direction of travel or drivewheels trailing a direction of travel). As may be realized, throughputoutbound from the storage array in the horizontal plane corresponding toa predetermined storage or deck level 130L is effected by and manifestin the combined or integrated throughput along both the asynchronous Xand Y transport axes. As noted above, the transfer deck(s) 130B alsoprovides bot 110 access to each of the lifts 150 on the respectivestorage level 130L where the lifts 150 feed and remove case units (e.g.along the Z throughput axis, see, e.g., FIGS. 2A, 2B, 3, 4A, and 4B) toand/or from each storage level 130L and where the bots 110 effect caseunit transfer between the lifts 150 and the storage spaces 130S.

In other aspects, of the disclosed embodiments, the transfer decks 130Bmay be deterministic, in a manner substantially similar to that of thepicking aisles. For example, the transfer decks 130B may include anysuitable number of guide features 130BS1, 130BS2, such as rails, guides,tracks, etc., which form one or more travel paths HSTP1, HSTP2 for thebots 110 and providing access to the lifts 150 (e.g., along theasynchronous X transport axis with respect to the bot frame of referenceREF illustrated in FIGS. 2A and 2B) across and along the transfer decks130B. The deterministic travel paths HSTP1, HSTP2 of the transfer decks130B may be arranged transverse to the picking aisles 130A of arespective level 130L. The bots 110 may be suitably configured totransition between rails 1200S of the deterministic picking aisle 130A(e.g., along the asynchronous Y transport axis with respect to the botframe of reference REF illustrated in FIGS. 2A and 2B) and adeterministic travel path HSTP1, HSTP2 in any suitable manner. Forexample, the bots 110 may include sets of substantially orthogonalwheels as described in, for example, U.S. Pat. No. 5,370,492, issued onDec. 6, 1994 and/or U.S. Pat. No. 6,389,981, issued on May 21, 2002, thedisclosures of which are incorporated herein by reference in theirentireties. In still other aspects, the bots 110 may include separabletraversal unit(s) that roll on and roll off of a bot main frame. Forexample, the bot main frame traverses the one of the deterministicpicking aisle 130A and the deterministic travel path(s) HSTP1, HSTP2 ofthe transfer deck 130B (e.g., along one of the asynchronous X and Yaxes) and the separable unit traverses another of the deterministicpicking aisle 130A and the deterministic travel path(s) HSTP1, HSTP2 ofthe transfer deck 130B (e.g., along another of the asynchronous X and Yaxes). Suitable examples of autonomous transports having a main frameand a separable traversal unit can be found in, for example, U.S. Pat.No. 4,459,078, issued Jul. 10, 1984, the disclosure of which isincorporated herein by reference in its entirety.

As described above, referring also to FIG. 3, in one aspect the storagestructure 130 includes multiple storage rack modules RM that areconfigured in a three dimensional array RMA, where the racks arearranged in aisles 130A and the aisles 130A are configured for bot 110travel within the aisles 130A. In this aspect, the transfer deck 130Bhas an undeterministic transport surface on which the bots 110 travelwhere the undeterministic transport surface 130BS has more than onejuxtaposed travel lane (e.g. high speed bot travel paths HSTP)connecting the aisles 130A (in other aspects, each high speed bot travelpath may be deterministic as noted above). As may be realized, thejuxtaposed travel lanes are juxtaposed along a common undeterministic(or deterministic as shown in FIG. 3A) transport surface 130BS betweenopposing sides 130BD1, 130BD2 of the transfer deck 130B. As illustratedin FIG. 3, in one aspect the aisles 130A are joined to the transfer deck130B on one side 130BD2 of the transfer deck 130B but in other aspects,the aisles are joined to more than one side 130BD1, 130BD2 of thetransfer deck 130B in a manner substantially similar to that describedin U.S. patent application Ser. No. 13/326,674 filed on Dec. 15, 2011,the disclosure of which was previously incorporated by reference hereinin its entirety. As will be described in greater detail below, the otherside 130BD1 of the transfer deck 130B includes deck storage racks (e.g.interface stations TS and buffer stations BS) that are distributed alongthe other side 130BD1 of the transfer deck 130B so that at least onepart of the transfer deck is interposed between the deck storage racks(such as, for example, buffer stations BS or transfer stations TS) andthe aisles 130A. The deck storage racks are arranged along the otherside 130BD1 of the transfer deck 130B so that the deck storage rackscommunicate with the bots 110 from the transfer deck 130B and with thelift modules 150 (e.g. the deck storage racks are accessed by the bots110 from the transfer deck 130B and by the lifts 150 for picking andplacing pickfaces so that pickfaces are transferred between the bots 110and the deck storage racks and between the deck storage racks and thelifts 150 and hence between the bots 110 and the lifts 150).

Referring again to FIG. 1A, each storage level 130L may also includecharging stations 130C for charging an on-board power supply of the bots110 on that storage level 130L such as described in, for example, U.S.Pat. No. 9,082,112 issued on Jul. 14, 2015, the disclosure of which isincorporated herein by reference in its entirety.

The bots 110 may be any suitable independently operable autonomoustransport vehicles that carry and transfer case units along theasynchronous X and Y transport axes throughout the storage and retrievalsystem 100. In one aspect the bots 110 are automated, independent (e.g.free riding) autonomous transport vehicles. Suitable examples of botscan be found in, for exemplary purposes only, U.S. patent applicationSer. No. 13/326,674 filed on Dec. 15, 2011; U.S. Pat. No. 8,425,173issued on Apr. 23, 2013; U.S. Pat. No. 9,561,905 issued on Feb. 7, 2017;U.S. Pat. No. 8,965,619 issued on Feb. 24, 2015; U.S. Pat. No. 8,696,010issued on Apr. 15, 2014; U.S. Pat. No. 9,187,244 issued on Nov. 17,2015; U.S. patent application Ser. No. 13/326,952 filed on Dec. 15,2011; U.S. Pat. No. 9,499,338 on Nov. 22, 2106; U.S. patent applicationSer. No. 14/486,008 filed on Sep. 15, 2014; and U.S. Pat. No. 9,850,079issued on Dec. 26, 2017, the disclosures of which are incorporated byreference herein in their entireties. Other suitable examples of bots,e.g., for use on deterministic transfer decks, can be found in U.S. Pat.No. 4,459,078 issued on Jul. 10, 1984; U.S. Pat. No. 5,370,492 issued onDec. 6, 1994; and U.S. Pat. No. 8,974,168 issued on Mar. 10, 2015, thedisclosures of which have previously been incorporated herein byreference in their entireties. The bots 110 (described in greater detailbelow) may be configured to place case units, such as the abovedescribed retail merchandise, into picking stock in the one or morelevels of the storage structure 130 and then selectively retrieveordered case units. As may be realized, in one aspect, the array oflevel asynchronous transport axes X and Y (e.g. pickface/case transportaxes) of the storage array are defined by the picking aisles 130A, atleast one transfer deck 130B, the bot 110 and the extendable endeffector (as described herein) of the bot 110 (and in other aspects theextendable end effector of the lifts 150 also, at least in part, definesthe asynchronous Y transport axis). The pickfaces/case units aretransported between an inbound section of the storage and retrievalsystem 100, where pickfaces inbound to the array are generated (such as,for example, input station 1601N) and a load fill section of the storageand retrieval system 100 (such as for example, output station 160UT),where outbound pickfaces from the array are arranged to fill a load inaccordance with a predetermined load fill order sequence of mixed cases.

As will be described herein, the transport of mixed case(s)/pickfacescoincident with transport on at least one of (or in other aspects on atleast one of each of the more than one of) the array of levelasynchronous transport axes X and Y is based on an infeed order sequence173 (FIG. 1A) to the lifting transport system 500 (FIGS. 1A and 5) thatmay be freely selected based any suitable optimization strategy of oneor more transactions of the respective asynchronous level transportsystem 191, a desired optimal transaction/action (e.g., pickface and/ortraverse along one or more level asynchronous transport axes X and Y), adistribution of case unit(s) within the storage structure 130 (e.g., oneach storage level 130L, one or more desired levels, and/or a desiredportion of one or more storage levels 130L), availability of a bot 110,and/or an availability of a lift 150. Different (or common) optimizationstrategy(ies) may be applied to the transactions/actions of one or moreasynchronous level transport systems 191 (or portions of one or moreasynchronous level transport systems 191) by, for example, controlserver 120. The optimization strategy(ies) include, but are not limitedto, a time optimal strategy favoring minimum times from pick aisle rackto lift infeed and/or load balancing across a level(s) (or portion(s) ofthe level(s)) so that the transaction rate at desired section of thelevel(s) (or portion(s) of the level(s)) is distributed substantiallyconstant for the given transaction (e.g., bot pick/places per hour) and,for example, approaching high (e.g., over 1000 transaction per hour for40 bots per level) throughput rates at the level(s) (or portion(s) of alevel(s)). Moreover, different optimization strategies may be appliedalong or in combination at different levels 130L or within on or moreportions of a common level 130L.

The infeed order sequence 173 forms an inferior ordered sequence ofmixed cases 170 (FIG. 1A—e.g., inferior sequencing in sequence order)relative to the predetermined case out ordered sequence of mixed cases172. As will also be described below, the resequencing of mixed casepickfaces coincident with the transport and output of the mixed casepickfaces by the lifting transport system 500 is decoupled from thetransport of mixed case(s)/pickfaces by the array of level asynchronoustransport axes X and Y, and where the ordered sequence of mixed cases171 forms a superior ordered sequence of mixed cases 171S (FIG. 1A—e.g.,a superior sequencing in sequence order) relative to the predeterminedcase out ordered sequence of mixed cases 172 (and the inferior orderedsequence of mixed cases 170 provided by the array of level asynchronoustransport axes X and Y).

The bots 110, lift modules 150 and other suitable features of thestorage and retrieval system 100 are controlled in any suitable mannersuch as by, for example, one or more central system control computers orcomputing environment (e.g. referred to as a “control server”) 120through, for example, any suitable network 180. The control server 120may be any suitable computing environment that includes a servercomputer or any other system providing computing capability. In otheraspects, the control server 120 may employ a plurality of computingdevices that may be arranged, for example, in one or more server banksor computer banks or other arrangements. Such computing devices may belocated in a single installation or may be distributed among one or moregeographical locations. For example, the control server 120 may includea plurality of computing devices that together form a hosted computingresource, a grid computing resource and/or any other distributedcomputing arrangement. In some aspects, the control server 120 forms anelastic computing resource where the allotted processing, network, andstorage capacities (or other computing resources) may change over time.In one aspect the network 180 is a wired network, a wireless network ora combination of wireless and wired networks using any suitable typeand/or number of communication protocols. Examples of the network 180include, but are not limited to, the Internet, intranets, extranets,wide area networks (WANs), local area networks (LANs), satellitenetworks, cable networks, Ethernet networks or any other suitablenetwork configuration.

In one aspect, the control server 120 includes a collection ofsubstantially concurrently running programs (e.g. system managementsoftware) for substantially automatic control of the automated storageand retrieval system 100. The collection of substantially concurrentlyrunning programs, for example, being configured to manage the storageand retrieval system 100 including, for exemplary purposes only,controlling, scheduling, and monitoring the activities of all activesystem components, managing inventory (e.g. which case units are inputand removed, the order in which the cases are removed and where the caseunits are stored) and pickfaces (e.g. one or more case units that aremovable as a unit and handled as a unit by components of the storage andretrieval system), and interfacing with a warehouse management system2500. In one aspect, the control server 120 may include, or havecommunicably coupled thereto, a number of component controllers120S1-120Sn that receive commands from the control server 120 formanaging operation of one or more components of the automated storageand retrieval system 100.

The control server 120 and/or component controllers 120S1-120Sn may, inone aspect, be configured to control the features of the storage andretrieval system in the manner described herein. For example, one ormore of the component controllers 120S1-120Sn may be responsible forassigning tasks to a respective one or more of the independent lift axis150X1-150Xn (based on, e.g., commands received from the control server120) so that each lift axis 150X1-150Xn, individually or collectively,output mixed case units at a common output of the lift axes 150X1-150Xnwhere the output case units have superior ordered sequence of mixedcases 171S in accordance to a predetermined superior case out orderedsequence of mixed cases as described herein. One or more other componentcontrollers 120S1-120Sn may be responsible for assigning tasks to arespective level 130L of the asynchronous level transport system 191 forcontrolling the respective level asynchronous transport axes X and Y forsupplying an inferior ordered sequence of mixed cases 170 to theindependent lift axis(es) (150X1-150Xn) as described herein.

Here the superior ordered sequence of mixed cases 171S is effectedthrough control of each lift axis 150X1-150Xn by one or more of one ormore of the control server 120 and the respective component controller120S1-120Sn. In one aspect, the control server 120 may include one ormore models 125 of the storage and retrieval system 100 and/or thecomponents (e.g., lift axes 150X1-150Xn, asynchronous level transportsystem(s) 191, etc.), where the one or more models 125 model performanceaspects, and constraints, of the storage and retrieval system componentsdescribed herein. The one or more models may, at least in part,determine transport trajectories for case units throughout the storageand retrieval system that are effected by one or more of the componentcontrollers 120S1-120Sn, so that the superior ordered sequence of mixedcases 171S is output at the common output of the lift axes 150X1-150Xn.The one or more models 125 may be updated, for example, via sensory andactuation data from the component controllers 120S1-120Sn, on asubstantially real time bases, enabling an “on the fly” or in motusdetermination of optimum case unit transport solutions (e.g., accountingfor receding planning horizon, level shutdown, autonomous vehiclefailure, lift module shutdown, storage pick action failure, storageput/place action failure, or any other disturbances that would disruptor otherwise affect storage and retrieval system operation) forgenerating the superior ordered sequence of mixed cases 171S over apredetermined time period.

Referring also to FIG. 1B the rack module array RMA of the storagestructure 130 includes vertical support members 1212 and horizontalsupport members/rails 1200 that define the high density automatedstorage array as described herein. Rails 1200S may be mounted to one ormore of the vertical and horizontal support members 1212, 1200 in, forexample, picking aisles 130A and be configured so that the bots 110 ridealong the rails 1200S through the picking aisles 130A. At least one sideof at least one of the picking aisles 130A of at least one storage level130L may have one or more storage shelves (e.g. formed by rails 1210,1200 and slats 1210S or other suitable case supports) provided atdiffering heights so as to form multiple shelf levels 130LS1-130LS4between the storage or deck levels 130L defined by the transfer decks130B (and the rails 1200S which form an aisle deck). Accordingly, thereare multiple rack shelf levels 130LS1-130LS4, corresponding to eachstorage level 130L, extending along one or more picking aisles 130Acommunicating with the transfer deck 130B of the respective storagelevel 130L. As may be realized, the multiple rack shelf levels130LS1-130LS4 effect each storage level 130L having stacks of storedcase units (or case layers) that are accessible from a common deck(e.g., formed by the rails 1200S) of a respective storage level 130L(e.g. the stacks of stored cases are located between storage levels).

As may be realized, bots 110 traversing a picking aisle 130A, at acorresponding storage level 130L, have access (e.g. for picking andplacing case units) to each storage space 130S that is available on eachshelf level 130LS1-130LS4, where each shelf level 130LS1-130LS4 islocated between adjacent vertically stacked storage levels 130L on oneor more side(s) PAS1, PAS2 (see e.g. FIG. 3) of the picking aisle 130A.As noted above, each of the storage shelf levels 130LS1-130LS4 isaccessible by the bot 110 from the rails 1200S (e.g. from a commonpicking aisle deck formed by the rails 1200S that corresponds with atransfer deck 130B on a respective storage level 130L). As can be seenin FIG. 1B there are one or more intermediate shelf rails 1210vertically spaced (e.g. in the Z direction) from one another (and fromrails 1200S) to form multiple stacked storage spaces 130S each beingaccessible by the bot 110 from the common rails 1200S. As may berealized, the horizontal support members 1200 also form shelf rails (inaddition to shelf rails 1210) on which case units are placed.

In one aspect, each stacked shelf level 130LS1-130LS4 (and/or eachsingle shelf level as described below) of a corresponding storage level130L defines an open and undeterministic two dimensional storage surface(e.g. having a case unit support plane CUSP as shown in FIG. 1B) thatfacilitates a dynamic allocation of pickfaces both longitudinally (e.g.along a length of the aisle or coincident with a path of bot traveldefined by the picking aisle) and laterally (e.g. with respect to rackdepth, transverse to the aisle or the path of bot travel). Dynamicallocation of the pickfaces and case units that make up the pickfaces isprovided, for example, in the manner described in U.S. Pat. No.8,594,835 issued on Nov. 26, 2013, the disclosure of which isincorporated by reference herein in its entirety. For example, thecontroller, such as control server 120 monitors the case units stored onthe shelves and the empty spaces or storage locations between the caseunits. The empty storage locations are dynamically allocated such that,for exemplary purposes only, one case having a first size is replaced bythree cases each having a second size which when combined fits into thespace previously reserved for the first size case, or vice versa.Dynamic allocation substantially continuously resizes the empty storagelocations as case units are placed on and removed from the storageshelves (e.g. the storage locations do not have a predetermined sizeand/or location on the storage shelves). As such, case unit (or tote)pickfaces of variable lengths and widths are positioned at each twodimensional storage location on the storage shelves (e.g. on eachstorage shelf level 130LS1-130LS4) with minimum gaps G (e.g. that effectpicking/placing of case units free from contact with other case unitsstored on the shelves, see FIG. 1B) between adjacent stored caseunits/storage spaces.

As described above, the spacing between the rails 1200, 1210 (e.g.storage shelves) is a variable spacing so as to minimize (e.g. provideonly sufficient clearance for insertion and removal of case units from arespective storage location) the vertical gap VG between verticallystacked case units. As will be described below (e.g., with respect tosections SECA, SECB in, e.g., FIGS. 1B and 3), in one aspect thevertical spacing between rails 1200, 1210 varies along a length of arespective picking aisle 130A while in other aspects the spacing betweenrails or horizontal support members 1200, 1210 may be substantiallycontinuous along a picking aisle 130A. As may be realized and asdescribed in greater detail below, the spacing between the rails 1200,1210 on one side PAS1 (FIG. 3) of a picking aisle 130A may be differentthan the spacing between rails 1200, 1210 on an opposite side PAS2 (FIG.3) of the same picking aisle 130A. As may be realized, any suitablenumber of shelves 1210 may be provided between the decks/rails 1200S ofadjacent vertically stacked storage levels 130L where the shelves havethe same or differing pitches between the shelves (e.g., case unitslocated in a vertical stack on one side of the picking aisle and caseunits located in a vertical stack on an opposite side of the pickingaisle on storage shelves having a substantially similar or differentpitches).

In one aspect of the disclosed embodiment, referring to FIG. 1B, avertical pitch between rack shelf levels 130LS1-130LS4 (that correspondsto each storage level 130L) is varied so that a height Z1A-Z1E betweenthe shelves is different, rather than equal to, for example, minimize avertical gap VG between an upper or top surface CUTS of a case unit CUand a bottom of the storage shelf (e.g., formed by rails 1200, 1210)located directly above the case unit. As can be seen in FIG. 1B,minimizing the gaps G, VG in both the horizontal and vertical directionsresults in a densely packed case unit arrangement within the storageshelves so as to form the high density three dimensional rack array RMAwhere, for example, the high density multi-level shelving aislesincreases throughput along the X throughput axis and enables anordered/sorted (e.g. according to the predetermined load out sequence)multi-pick of two or more case units from a common picking aisle in onecommon pass of the picking aisle as will be described below. Forexample, still referring to FIG. 1B, one section SECB of the storagelevel 130L includes two storage shelves (e.g., formed by rails 1200,1210) where one shelf has a pitch of Z1A and the other shelf has a pitchof Z1B where Z1A and Z1B are different from each other. This differingpitch allows for the placement of case units CUD, CUE having differingheights in a stack one above the other on a common storage level 130L.In other aspects pitches Z1A, Z1B may be substantially the same. In thisaspect the storage level 130L includes another storage section SECA thathas three storage shelves where one shelf has a pitch of Z1E, onestorage shelf has a pitch of Z1D and the other storage shelf has a pitchof Z1C where Z1E, Z1D and Z1C are different from each other. In otheraspects at least two of the pitches Z1E, Z1D and Z1C are substantiallythe same. In one aspect the pitch between the shelves is arranged sothat larger and/or heavier case units CUC, CUE are arranged closer tothe deck/rail 1200S than smaller and/or lighter case units CUD, CUA,CUB. In other aspects the pitch between the shelves is arranged so thatthe case units are arranged in any suitable positions that may or maynot be related to case unit size and weight.

In other aspects, the vertical pitch between at least some of the rackshelves is the same so that the height Z1A-Z1E between at least someshelves is equal while the vertical pitch between other shelves isdifferent. In still other aspects, the pitch of rack shelf levels130LS1-130LS4 on one storage level is a constant pitch (e.g. the rackshelf levels are substantially equally spaced in the Z direction) whilethe pitch of rack shelf levels 130LS1-130LS4 on a different storagelevel is a different constant pitch.

In one aspect, the storage space(s) 130S defined by the storage shelflevels 130LS1-130LS4 between the storage or deck levels 130Laccommodates case units of different heights, lengths, widths and/orweights at the different shelf levels 130LS1-130LS4 as described in, forexample, U.S. Pat. No. 9,884,719 issued on Feb. 6, 2018, the disclosureof which is incorporated by reference herein in its entirety. Forexample, still referring to FIG. 1B the storage level 130L includesstorage sections having at least one intermediate shelf 1210. In theexample shown, one storage section includes one intermediate shelf/rail1210 while another storage section includes two intermediateshelves/rail 1210 for forming shelf levels 130LS1-130LS4. In one aspectthe pitch Z1 between storage levels 130L may be any suitable pitch suchas, for example, about 32 inches to about 34 inches while in otheraspects the pitch may be more than about 34 inches and/or less thanabout 32 inches. Any suitable number of shelves may be provided betweenthe decks/rails 1200S of adjacent vertically stacked storage levels 130Lwhere the shelves have the same or differing pitches between theshelves.

In one aspect of the disclosed embodiment the storage or deck levels130L (e.g. the surface on which the bots 110 travel) are arranged at anysuitable predetermined pitch Z1 that is not, for example, an integermultiple of the intermediate shelf pitch(es) Z1A-Z1E. In other aspectsthe pitch Z1 may be an integer multiple of the intermediate shelf pitch,such as for example, the shelf pitch may be substantially equal to thepitch Z1 so that the corresponding storage space has a heightsubstantially equal to the pitch Z1. As may be realized, the shelf pitchZ1A-Z1E is substantially decoupled from the storage level 130L pitch Z1and corresponds to general case unit heights as illustrated in FIG. 1B.In one aspect of the disclosed embodiment case units of differentheights are dynamically allocated or otherwise distributed along eachaisle within a storage space 130S having a shelf height commensuratewith the case unit height. The remaining space between the storagelevels 130L, both along the length of the aisle coincident with thestored case unit (e.g. in the X direction with respect to the rack frameof reference REF2 (see, e.g., FIG. 3) where the X direction is the samein the bot frame of reference REF (see, e.g., FIGS. 2A and 2B) as thebot travels through a picking aisle 130A) and alongside the stored caseunit, being freely usable for dynamic allocation for cases of acorresponding height. As may be realized, the dynamic allocation of caseunits having different heights onto shelves having different pitchesprovides for stored case layers of different heights, between storagelevels 130L on both sides of each picking aisle 130A, with each caseunit being dynamically distributed along a common picking aisle 130A sothat each case unit within each stored case layer being independentlyaccessible (e.g. for picking/placing) by the bot in the common aisle.This high density placement/allocation of case units and the arrangementof the storage shelves provides maximum efficiency of storagespace/volume use between the storage levels 130L, and hence of maximumefficiency of the rack module array RMA, with optimized distribution ofcase unit SKU's, as each aisle length may include multiple case units ofdifferent heights, yet each rack shelf at each shelf level may be filledby dynamic allocation/distribution (e.g. to fill the three dimensionalrack module array RMA space in length, width and height, to provide ahigh density storage array).

In one aspect, referring to FIGS. 1C and 2B each of the storage levels130L includes a single level of storage shelves to store a single levelof case units (e.g. each storage level includes a single case unitsupport plane CUSP) and the bots 110 are configured to transfer caseunits to and from the storage shelves of the respective storage level130L. For example, the bot 110′ illustrated in FIG. 2B is substantiallysimilar to bot 110 described herein however, the bot 110′ is notprovided with sufficient Z-travel of the transfer arm 110PA for placingcase units on the multiple storage shelf levels 130LS1-130LS4 (e.g.accessible from a common rail 1200S as shown in, e.g., FIG. 1B) asdescribed above. Here the transfer arm drive 250 (which may besubstantially similar to one or more of drive 250A, 250B) includes onlysufficient Z-travel for lifting the case units from the case unitsupport plane CUSP of the single level of storage shelves, fortransferring the case units to and from the payload area 110PL and fortransferring the case units between the fingers 273 of the transfer arm110PA and the payload bed 110PB. Suitable examples of bots 110′ can befound in, for example, U.S. Pat. No. 9,499,338 issued on Nov. 22, 2106,the disclosure of which is incorporated herein by reference in itsentirety.

In one aspect of the disclosed embodiment, referring also to FIG. 3, therack shelves 1210 (inclusive of the rack shelf formed by rail 1200) aresectioned SECA, SECB longitudinally (e.g. along the length of thepicking aisle 130A in the X direction, with respect to a storagestructure frame of reference REF2) to form ordered or otherwise matchedrack shelf sections along each picking aisle 130A. The aisle shelfsections SECA, SECB are ordered/matched to each other based on, forexample, a pick sequence of a bot 110 traversing the aisle in a commonpass picking case units destined for a common order fill (e.g. based onthe order out sequence). In other words, a bot 110 makes a single pass(e.g. traversal in a single direction) down a single or common pickingaisle while picking one or more case units from aisle shelf sectionsSECA, SECB on a common side of the picking aisle 130A to build apickface on the bot 110 where the pickface includes case units that arearranged on the bot according to, for example, the infeed order sequence173 (FIG. 1A) to the lifting transport system 500. Each of the aislerack sections SECA, SECB includes intermediate shelves in the mannerdescribed above. In other aspects some of the aisle shelves do notinclude intermediate shelves while others do include intermediateshelves.

In one aspect, the ordered aisle rack sections SECA, SECB include shelfpitches that are different between sections SECA, SECB. For example,aisle rack section SECA has shelves with one or more pitches while aislerack section SECB has shelves with one or more different pitches (e.g.different than the pitches of the shelves in section SECA). Inaccordance with the aspects of the disclosed embodiment, the pitch of atleast one intermediate shelf of one aisle rack section SECA, SECB isrelated to the pitch of at least one intermediate shelf of another ofthe ordered aisle rack sections SECA, SECB of the common picking aisle130A. The different pitches of the intermediate shelves/rails 1210 inthe ordered aisle rack section SECA, SECB are selected so as to berelated and to effect multiple (at least two) ordered picks (i.e. picksin an ordered sequence) with a bot 110, in accordance with a mixed SKUload out sequence (e.g. palletizing to a common pallet load), fromshelves of different pitches, from a common pass of a common pickingaisle 130A. As may be realized, the mixed load output from the storageand retrieval system 100 (e.g. to fill a truck loadport/pallet load) issequenced in a predetermined order according to various load out pickingaisles (e.g. aisles from which case units are picked for transfer to anoutgoing pallet) and the shelf pitch in the ordered sections SECA, SECBfacilitates a bot 110 pick of more than one case unit in orderedsequence according to an order of the load out sequence in a commonpicking aisle pass (e.g. more than one case unit is picked in apredetermined order from a common picking aisle in one pass of thecommon picking aisle). The different aisle shelf pitches of the orderedrack sections SECA, SECB are so related to increase the probability ofsuch an ordered multi-pick (the picking of two or more case units from asingle aisle with a single pass of the aisle as described above) so thatthe multi-pick is performed by each bot order fulfillment pass alongeach aisle, and so related such that more than a majority of casespicked in the storage and retrieval system 100 by the bots 110 anddestined for a common load out (e.g. a common pallet load) are picked bya common bot 110 according to the infeed order sequence 173 to thelifting transport system 500 (e.g. the two or more cases picked by thebot 110 are picked from the same picking aisle in a single pass, e.g.the bot travels in a single direction once through the picking aisle).As may be realized, in one aspect of the disclosed embodiment both sidesPAS1, PAS2 of the picking aisle 130A have ordered aisle rack sectionsSECA, SECB where one ordered section may be matched with one or moresections on the same side PAS1, PAS2 of the common picking aisle 130A.As may be realized, the matched aisle rack sections may be locatedadjacent one another or spaced apart from one another along the pickingaisle 130A.

Referring again to FIG. 3 each transfer deck or storage level 130Lincludes one or more lift pickface interface/handoff stations TS(referred to herein as interface stations TS) where case unit(s) (ofsingle or combined case pickfaces) or totes are transferred between thelift load handling devices LHD and bots 110 on the transfer deck 130B.The interface stations TS are located at a side of the transfer deck130B opposite the picking aisles 130A and rack modules RM, so that thetransfer deck 130B is interposed between the picking aisles and eachinterface station TS. As noted above, each bot 110 on each picking level130L has access to each storage location 130S, each picking aisle 130Aand each lift 150 on the respective storage level 130L, as such each bot110 also has access to each interface station TS on the respective level130L. In one aspect the interface stations are offset from high speedbot travel paths HSTP along the transfer deck 130B so that bot 110access to the interface stations TS is undeterministic to bot speed onthe high speed travel paths HSTP. As such, each bot 110 can move a caseunit(s) (or pickface, e.g. one or more cases, built by the bot) fromevery interface station TS to every storage space 130S corresponding tothe deck level and vice versa.

In one aspect the interface stations TS are configured for a passivetransfer (e.g. handoff) of case units (and/or pickfaces) between the bot110 and the load handing devices LHD of the lifts 150 (e.g. theinterface stations TS have no moving parts for transporting the caseunits) which will be described in greater detail below. For example,also referring to FIG. 6C the interface stations TS and/or bufferstations BS include one or more stacked levels TL1, TL2 of transfer rackshelves RTS (e.g. so as to take advantage of the lifting ability of thebot 110 with respect to the stacked rack shelves RTS) which in oneaspect are substantially similar to the storage shelves described above(e.g. each being formed by rails 1210, 1200 and slats 1210S, or othersuitable case unit support structure) such that bot 110 handoff (e.g.pick and place) occurs in a passive manner substantially similar to thatbetween the bot 110 and the storage spaces 130S (as described herein)where the case units or totes are transferred to and from the shelves.In one aspect the buffer stations BS on one or more of the stackedlevels TL1, TL2 also serve as a handoff/interface station with respectto the load handling device LHD of the lift 150. In one aspect, wherethe bots, such as bots 110′, are configured for the transfer of caseunits to a single level 130L of storage shelves, the interface stationsTS and/or buffer stations BS also include a single level of transferrack shelves (which are substantially similar to the storage rackshelves of the storage levels 130L described above with respect to, forexample, FIG. 1C). As may be realized, operation of the storage andretrieval system with bots 110′ serving the single level storage andtransfer shelves is substantially similar to that described herein. Asmay also be realized, load handling device LHD handoff (e.g. pick andplace) of case units (e.g. individual case units or pickfaces) and totesto the stacked rack shelves RTS (and/or the single level rack shelves)occurs in a passive manner substantially similar to that between the bot110 and the storage spaces 130S (as described herein) where the caseunits or totes are transferred to and from the shelves. In other aspectsthe shelves may include transfer arms (substantially similar to the bot110 transfer arm 110PA shown in FIGS. 2A and/or 2B, although Z directionmovement may be omitted when the transfer arm is incorporated into theinterface station TS shelves) for picking and placing case units ortotes from one or more of the bot 110 and load handling device LHD ofthe lift 150. Suitable examples of an interface station with an activetransfer arm are described in, for example, U.S. Pat. No. 9,694,975issued on Jul. 4, 2017, the disclosure of which is incorporated byreference herein in its entirety.

In one aspect, the location of the bot 110 relative to the interfacestations TS occurs in a manner substantially similar to bot locationrelative to the storage spaces 130S. For example, in one aspect,location of the bot 110 relative to the storage spaces 130S and theinterface stations TS occurs in a manner substantially similar to thatdescribed in U.S. Pat. No. 9,008,884 issued on Apr. 14, 2015 and U.S.Pat. No. 8,954,188 issued on Feb. 10, 2015, the disclosures of which areincorporated herein by reference in their entireties. For example,referring to FIGS. 1A and 1C, the bot 110 includes one or more sensors110S that detect the slats 1210S or a locating feature 130F (such as anaperture, reflective surface, RFID tag, etc.) disposed on/in the rail1200S. The slats 1210S and/or locating features 130F are arranged so asto identify a location of the bot 110 within the storage and retrievalsystem, relative to e.g. the storages spaces and/or interface stationsTS. In one aspect the bot 110 includes a controller 110C that, forexample, counts the slats 1210S to at least in part determine a locationof the bot 110 within the storage and retrieval system 100. In otheraspects the location features 130F may be arranged so as to form anabsolute or incremental encoder which when detected by the bot 110provides for a bot 110 location determination within the storage andretrieval system 100.

As may be realized, referring to FIGS. 3 and 6B, the transfer rackshelves RTS at each interface/handoff station TS, in one aspect, definemulti-load stations (e.g. having one or more storage case unit holdinglocations for holding a corresponding number of case units or totes) ona common transfer rack shelf RS. As noted above, each load of themulti-load station is a single case unit/tote or a multi-case pickface(e.g. having multiple case units/totes that are moved as a single unit)that is picked and paced by either the bot or load handling device LHD.As may also be realized, the bot location described above allows for thebot 110 to position itself relative to the multi-load stations forpicking and placing the case units/totes and pickfaces from apredetermined one of the holding locations of the multi-load station.The interface/handoff stations TS define multi-place buffers (e.g.buffers having one or more case holding location—see FIG. 5C—arrangedalong, for example, the X axis of the bot 110 as the bot 110 interfaceswith the interface station TS) where inbound and/or outbound caseunits/totes and pickfaces are temporarily stored when being transferredbetween the bots 110 and the load handling devices LHD of the lifts 150.

In one aspect one or more peripheral buffer/handoff stations BS(substantially similar to the interface stations TS and referred toherein as buffer stations BS) are also located at the side of thetransfer deck 130B opposite the picking aisles 130A and rack modules RM,so that the transfer deck 130B is interposed between the picking aislesand each buffer station BS. The peripheral buffer stations BS areinterspersed between or, in one aspect as shown in FIG. 3, otherwise inline with the interface stations TS. In one aspect the peripheral bufferstations BS are formed by rails 1210, 1200 and slats 1210S and are acontinuation of (but a separate section of) the interface stations TS(e.g. the interface stations and the peripheral buffer stations areformed by common rails 1210, 1200). As such, the peripheral bufferstations BS, in one aspect, also include one or more stacked levels TL1,TL2 of transfer rack shelves RTS as described above with respect to theinterface stations TS while in other aspects the buffer stations includea single level of transfer rack shelves. The peripheral buffer stationsBS define buffers where case units/totes and/or pickfaces aretemporarily stored when being transferred from one bot 110 to anotherdifferent bot 110 on the same storage level 130L as will be described ingreater detail below. As maybe realized, in one aspect the peripheralbuffer stations are located at any suitable location of the storage andretrieval system including within the picking aisles 130A and anywherealong the transfer deck 130B.

Still referring to FIGS. 3 and 6B in one aspect the interface stationsTS are arranged along the transfer deck 130B in a manner akin to parkingspaces on the side of a road such that the bots 110 “parallel park” at apredetermined interface station TS for transferring case units to andfrom one or more shelves RTS at one or more levels TL1, TL2 of theinterface station TS. In one aspect, a transfer orientation of the bots110 (e.g. when parallel parked) at an interface station TS is the sameorientation as when the bot 110 is travelling along the high speed bottransport path HSTP (e.g. the interface station is substantiallyparallel with a bot travel direction of the transfer deck and/or a sideof the transfer deck on which the lifts 150 are located). Bot 110interface with the peripheral buffer stations BS also occurs by parallelparking so that a transfer orientation of the bots 110 (e.g. whenparallel parked) at a peripheral buffer station BS is the sameorientation as when the bot 110 is travelling along the high speed bottransport path HSTP.

The outbound lifts 150B in FIG. 3 are representative of the lifting andtransport system 500 where the outbound lifts 150B have a common output300 that is supplied case units from a traverse 550, as describedherein. The common output 300 may form or be connected to one or moreconveyor sections 160CBT, 160CBL, 160CBR for transporting the case unitsoutput by the lifting and transport system 500 to one or more sides ofpalletizer 160PB. In another aspect, one or more of the outbound lifts150B may be representative of a lifting and transport system 500 suchthat a plurality of lifting and transport systems 500 are disposed alongthe transfer deck 130B. Here each respective lifting and transportsystem 500 may have a common output 300′ that is coupled to, forexample, the conveyor section 160CBT for transporting case units to oneor more of conveyors sections 160CBR, 160CBL (e.g., to one or more sidesof the palletizer 160PB). The conveyor section 160CBT may bebidirectional so that case units can be transferred between theplurality of lifting and transport systems 500.

In another aspect, referring to FIG. 4A, at least the interface stationsTS are located on an extension portion or pier 130PR that extends fromthe transfer deck 130B. In one aspect, the pier 130PR is similar to thepicking aisles where the bot 110 travels along rails 1200S affixed tohorizontal support members 1200 (in a manner substantially similar tothat described above). In other aspects, the travel surface of the pier130PR may be substantially similar to that of the transfer deck 130B.Each pier 130PR is located at the side of the transfer deck 130B, suchas a side that is opposite the picking aisles 130A and rack modules RM,so that the transfer deck 130B is interposed between the picking aislesand each pier 130PR. The pier(s) 130PR extends from the transfer deck ata non-zero angle relative to at least a portion of the high speed bottransport path HSTP. In other aspects the pier(s) 130PR extend from anysuitable portion of the transfer deck 130B including the ends 130BE1,130BE2 of the transfer deck 130B. As may be realized, peripheral bufferstations BSD (substantially similar to peripheral buffers stations BSdescribed above) may also be located at least along a portion of thepier 130PR.

As can be seen in FIG. 4A, lifts 150 (outbound lift modules 150B andinbound lift modules 150A) are disposed adjacent respective piers 130PRin a manner similar to that described herein where the lifts 150 aredisposed adjacent the transfer stations TS and buffer stations BS of thetransfer deck 130B (see, e.g., FIGS. 3 and 5A). In FIG. 4A, a singlerepresentative lift 150A, 150B is illustrated adjacent each pier 130PR;however, it should be understood that the single representative lift150A, 150B may be representative of one or more lifts 150. Inparticular, one or more of the single representative outbound lifts 150Bmay be representative of the lifting transport system 500 describedherein. In this aspect, the common output 300 includes one or moreconveyor sections 160CBT, 160CBR, 160CBL, where at least one of theconveyors sections is bidirectional. For example, conveyor section160CBT may be bidirectional so as to transfer case units to either oneof conveyors sections 160CBL, 160CBR (e.g., to either side of thepalletizer 160PB) and/or to transfer case units between lifting andtransport systems 500 connected to the conveyor section 160CBT to effectresequencing of case units to the (superior) ordered sequence of mixedcases 171 in the manner described herein. In other aspects, such aswhere a single outbound lift 150B is disposed at a pier 130PR, theconveyor section 160CBT may function as the traverse 550 so that caseunits can be transferred between outbound conveyors 150B of the piers130PR to effect resequencing of case units to the (superior) orderedsequence of mixed cases 171 in the manner described herein. In stillother aspects, there may be a plurality of lifting and transportsections 500 disposed on a common side of a common pier 130PR (e.g., oneor more of the single representative outbound lifts 150B may berepresentative of a plurality of lifting and transport sections 500) ina manner substantially similar to that described above with respect toFIG. 3 where the plurality of lifting and transport sections 500 aredisposed along the transfer deck 130B.

While FIG. 4A illustrates the lifting and transport systems 500 on asingle side of a respective pier 130PR, in other aspects there may be alifting and transport system 500 disposed on opposite sides of the pier130PR as illustrated in FIG. 4B. In FIG. 4B, the common output 300includes conveyor section 160CBT. The conveyor section 160CBT may bebidirectional so as to transport case units between the lifting andtransport systems 500 disposed on the opposite sides of the pier 130PR.As may be realized, where case units are transferred between lifting andtransport systems 500, the traverse 550 of the respective lifting andtransport system 500 may be bidirectional so as to transport the caseunits to any one or more of the lift axes 150X1-150Xn of the respectivelifting and transport system 500 for resequencing the case units asdescribed herein.

Referring now to FIGS. 5A, 5B, 5C, 6A, and 6B, as described above, inone aspect the interface stations TS are passive stations and as suchthe load transfer device LHD of the lifts 150 have one or more activetransfer arm or pick head 4000A. In one aspect the inbound lift modules150A and the outbound lift modules 150B may have different types of pickheads while in other aspects the inbound lift modules 150A and theoutbound lift modules 150B have the same type of pick head as describedin, for example, U.S. Pat. No. 9,856,083 issued on Jan. 2, 2018 (U.S.application Ser. No. 14/997,920), the disclosure of which isincorporated herein by reference in its entirety. In one aspect, the oneor more pick head 4000A of the lifts 150 may, at least in part, definethe asynchronous transport axis Y, while in other aspects, the Ydirection movement of the one or more pick head 4000A may be separateand distinct from the asynchronous transport axis Y.

In one aspect, the lifts 150 (e.g., both the inbound and outbound lifts150A, 150B) have a vertical mast 4002 along which a slide 4001 travelsunder the motive force of any suitable drive unit 4002D (e.g. connectedto, for example, control server 120) configured to lift and lower theslide (and the one or more pick heads 4000A mounted thereto as well asany case units disposed on the one or more pick head 4000A). The lifts150 include one or more pick head 4000A mounted to the slide 4001 sothat as the slide moves vertically the one or more pick head 4000A movesvertically with the slide 4001. In the aspect illustrated in FIGS. 5A-5Cthe one or more pick head 4000A includes one or more tines or fingers4273 mounted to a base member 4272. The base member 4272 is movablymounted to one or more rail 4360S of frame 4200 which in turn is mountedto the slide 4001. Any suitable drive unit 4005, such as a belt drive,chain drive, screw drive, gear drive, etc. (which is substantiallysimilar in form but may not be similar in capacity to drive 4002D as thedrive 4005 may be smaller than drive 4002D) is mounted to the frame 4200and coupled to the base member 4272 for driving the base member 4272(with the finger(s)) in the direction of arrow 4050. While a single pickhead 4000A is illustrated in FIGS. 5A-6B, in other aspects there may betwo or more independently pick head portions on a common lift 150 asdescribed in U.S. Pat. No. 9,856,083. In addition, while the one or morepick head 4000A is illustrated in FIGS. 5A-6B as being disposed on asingle side of vertical mast 4002, in other aspects, a pick head 4000(substantially similar to the one or more of pick head 4000A) may extendfrom an opposite side of the vertical mast 4002 than the one or morepick head 4000A. The pick head 4000 may be mounted to the same slide4001 as the one or more pick head 4000A so as to move vertically alongthe vertical mast 4002 as a unit with the one or more pick head 4000A.In other aspects, the pick head 4000 may be mounted to a separate anddistinct slide 4001A so that the pick heads 4000 and 4000A can each moveindividually vertically along the vertical mast 4002 independent of(e.g., separate from) each other. The opposingly extended pick heads maybe employed where there are transfer stations TS (or buffer stations BS)disposed on opposite sides of the vertical mast 4002.

Referring to FIG. 5A, the lifts 150 (at least the outbound lifts 150B)are arranged adjacent one another (e.g., side by side substantially in arow) so as to form the lifting transport system 500 with the more thanone independent lift axis 150X1-150Xn arrayed in at least one direction.In other aspects, as illustrated in FIG. 5D, the lifts 150 (at least theoutbound lifts) are arranged in a two dimensional array of more than oneindependent lift axis so as to form the lifting transport system 500.Each row 599R1, 599R2 (two rows are shown for exemplary purposes but itshould be understood that there may be any suitable number of rows) mayinclude any suitable number of lifts 150X1-150Xn, 150AX1-150AXn andthere may be any suitable number of columns 599C1-599Cn. As may berealized, at least a transport path for bots 110 (indicated by the level130L in FIG. 5D) and different infeed stations 556 may be provided foreach row 599R1, 599R2 of lifts 150. There may also be a traverse 550corresponding to each row 599R1, 599R2 of lifts 150, where the traverse550 of the different rows 599R1, 599R2 may merge into a common output300. In other aspects, the traverse 550 of the different rows 599R1,599R2 may not merger into a common output. An infeed interface 555communicably couples the multi-level transport system 190 with each ofthe more than one independent lift axis 150X1-150Xn. The infeedinterface 555 includes different infeed stations 556 (FIG. 5A)distributed at each asynchronous level transport system 191 for each ofthe more than one independent lift axis 150X1-150Xn (and/or150AX1-150AXn) so that each of the more than one independent lift axis150X1-150Xn (and/or 150AX1-150AXn) has a different corresponding infeedstation 556 at each asynchronous level transport system 191 throughwhich mixed cases feed from the multi-level transport system 190 to eachof the more than one independent lift axis 150X1-150Xn (and/or150AX1-150AXn).

Each of the independent lift axes 150X1-150Xn (it is noted that (liftaxes 150AX1-150AXn are substantially similar to lift axes 150X1-150Xnand any description of lift axes 150X1-150Xn equally applies to liftaxes 150AX1-150AXn) are communicably coupled to each asynchronous leveltransport system 191 (a portion of which is illustrated in FIG. 5),through the infeed interface 555, so as to provide for exchange of atleast one case unit CU between each asynchronous level transport system191 and each independent lift axis 150X1-150Xn. For example, eachindependent lift axis 150X1-150Xn is communicably coupled to each levelasynchronous transport axis X and Y of the array of level asynchronoustransport axes corresponding to each asynchronous level transport system191. The communicable coupling between the independent lift axes150X1-150Xn and each asynchronous level transport system 191 alsoprovides for mixed cases being transferred from at least oneasynchronous level transport system infeed (e.g., such as the infeedinterface 555 (e.g., which includes a respective transfer station TS orrespective buffer station BS) between an inbound lift 150A and arespective one of the levels 130L) to each of the more than oneindependent lift axis 150X1-150Xn so that mixed cases are output by theindependent lift axis 150X1-150Xn from the multi-level transport system190. In one aspect, the mixed cases are output substantiallycontinuously through the common output 300 in a predetermined case outordered sequence of mixed cases 172 decoupled from an available sequenceof mixed cases (e.g., an infeed order sequence 173) from and created bythe multi-level transport system 190 at the infeed interface 555 andthat feed the more than one independent lift axis 150X1-150Xn throughthe infeed interface 555. The more than one independent lift axis150X1-150Xn of the lifting transport system 500 define a lift transportstream 999 (see, e.g., FIGS. 8, 8B, 8C, 10, 10C, 12, and 12C) of mixedcases from the infeed interface 555, where the lift transport stream 800has the available sequence of mixed cases (e.g., an infeed ordersequence 173), to the common output 300 where the lift transport stream800 has the predetermined case out ordered sequence of mixed cases 172,and at least one lift axis 150X1-150Xn from the more than oneindependent lift axis 150X1-150Xn defines a pass through or pass by(e.g., bypass) with respect to another of the more than one independentlift axis 150X1-150Xn effecting on the fly/in motus resequencing fromthe available sequence of mixed cases (e.g., an infeed order sequence173) in the lift transport stream 999 to the predetermined case outordered sequence of mixed cases 172 at the common output 300.

Each independent lift axis 150X1-150Xn, of the more than one lift axis150X1-150Xn, is communicably coupled to each other independent lift axis150X1-150Xn of the more than one lift axis 150X1-150Xn and forms or isotherwise communicably coupled to a common output 300 (see FIGS. 1A, 3,4A, and 4B—also referred to as a common lift transport output) of mixedcases output by each of the more than one independent lift axis150X1-150Xn. The more than one independent lift axis 150X1-150Xncommonly outputs the mixed cases from the lifting transport system 500through the common output 300. For example, still referring to FIG. 5A,each independent lift axis 150X1-150Xn has a corresponding outputsection 520 and a traverse 550 operably connecting the correspondingoutput section 520 of each independent lift axis 150Xa-150Xn to thecommon output 300 so that mixed cases from each independent lift axis150X1-150Xn reach the common output 300 via the traverse 550. Asillustrated in FIG. 5A, the traverse 550 operably interconnects at leasttwo of the independent lift axis 150X1-150Xn. As described herein, thetraverse 550 is configured so as to form an alternate/bypass path formixed cases transported and output by the more than one independent liftaxis 150X1-150Xn of the lifting transport system 500 effectingresequencing, at least in part, from the inferior ordered sequence ofmixed cases 170, at infeed of the lifting transport system 500, to thesuperior ordered sequence of mixed cases 171S, at output of the liftingtransport system 500; where the inferior ordered sequence of mixed cases170 and the superior ordered sequence of mixed cases 171S respectivelyare of inferior sequencing in sequence order and superior sequencing insequence order relative to the predetermined case out ordered sequenceof mixed cases 172.

The more than one lift axis 150X1-150Xn are configured so as to create,at and from the common output 300, an ordered sequence of mixed cases inaccordance to a predetermined case out ordered sequence of mixed cases172. As described in greater detail herein, the more than oneindependent lift axis 150X1-150Xn are configured so as to resequence themixed case units (e.g., received from the asynchronous level transportsystem(s) 191) and effect a change in the ordered sequence of the mixedcases, with the lifting transport system 500 on the fly (in motus), fromthe inferior ordered sequence of mixed cases 170 (FIG. 1A), at theinfeed (e.g., such as at the transfer stations TS or buffer stations BSof the outbound lifts 150B) of the lifting transport system 500, to thesuperior ordered sequence of mixed cases 171S (FIG. 1A), at the commonoutput 300 of the lifting transport system 500. For example, inconjunction with or in lieu of alternate/bypass path for mixed casesformed by the traverse 550, at least one independent lift axis150X1-150Xn is configured so as to form an alternate/bypass path formixed cases transported and output by the more than one independent liftaxis 150X1-150Xn of the lifting transport system 500 effectingresequencing, at least in part, from the inferior ordered sequence ofmixed cases 170, at the infeed of the lifting transport system 500, tothe superior ordered sequence of mixed cases 171S, at the output of thelifting transport system 500.

The superior ordered sequence of mixed cases 171S at the common output300 is created on the traverse 550, and substantially within the boundsdefined by the outermost independent lift axes (which as illustrated inFIG. 5A would be the independent lift axes 150X1 and 150Xn at theextreme ends of the row of independent lift axes 150X1-150Xn). Thesuperior ordered sequence of mixed cases 171S (e.g., the orderedsequence of mixed cases created at and from the common output inaccordance to the predetermined case out ordered sequence of mixed cases172) is produced substantially continuously and consistent with, forexample, a high speed (over 500, and in one aspect over 1000, transferactions per hour on a pallet) pallet builder (e.g., palletizer 160PB)building at least one mixed case pallet layer of mixed laterallydistributed and stacked mixed cases (as illustrated and described withrespect to FIG. 1D). The superior ordered sequence of mixed cases 171Sis characterized by its sequence order of mixed case units thatconverges upon or nears the predetermined case out ordered sequence ofmixed cases 172 so that there is a strong correlation between respectivesequence orders of the superior ordered sequence of mixed cases 171S andthe predetermined case out ordered sequence of mixed cases 172. Thestrong correlation may be such that the sequence order, of the superiorordered sequence of mixed cases 171S, is a near net sequence order tothat of the predetermined case out ordered sequence of mixed cases 172.The inferior ordered sequence of mixed cases 170 is characterized by itssequence order of mixed cases that diverges from or is substantiallyneutral to the predetermined case out ordered sequence of mixed cases172 so that there is a weak correlation (compared to the strongcorrelation of the superior ordered sequence of mixed cases 171S)between respective sequence orders of the inferior ordered sequence ofmixed cases 170 and the predetermined case out ordered sequence of mixedcases 172.

As may be realized, the lift modules 150A, 150B and traverse 550 areunder the control of any suitable controller, such as control server120, such that when picking and placing case unit(s) the pick head israised and/or lowered to a predetermined height corresponding to, forexample, an interface station TS at a predetermined storage level 130Land/or the traverse 550 (e.g., to at least in part resequence the mixedcases). As may be realized, the lift modules 150A, 150B provide the Ztransport axis (relative to both the bot frame of reference REF and therack frame of reference REF2) of the storage and retrieval system 100where the output lift modules 150B sort case units on the fly (in motus)for delivery to the output stations 160US as will be described below. Atthe interface stations TS the pick head 4000A, 4000B or individualportion thereof (e.g. effector LHDA, LHDB), corresponding to one or morecase unit holding location(s) of the interface station TS from which oneor more case unit(s) are being picked, is extended so that the fingers4273 are interdigitated between the slats 1210S (as illustrated in FIG.4B) underneath the case unit(s) being picked (i.e., underneath thepickface formed by the case(s) being picked). The lift 150A, 150B raisesthe pick head 4000A, 4000B to lift the case unit(s) from the slats 1210Sand retracts the pick head 4000A, 4000B for transport of the caseunit(s) to another level of the storage and retrieval system, such asfor transporting the case unit(s) to output station 160UT. Similarly, toplace one or more case unit(s) the pick head 4000A, 4000B or individualportion thereof (e.g. effector LHDA, LHDB), corresponding to one or morecase unit holding location(s) of the interface station TS from which oneor more case unit(s) are being placed, is extended so that the fingers4273 are above the slats. The lift 150A, 150B lowers the pick head4000A, 4000B to place the case unit(s) on the slats 1210S and so thatthe fingers 4273 are interdigitated between the slats 1210S underneaththe case unit(s) being picked. In other aspects, the lift may have anysuitable configuration for picking and placing case unit(s) from and tothe interface station(s) TS. For example the pick head 4000A, 4000B maybe configured with arms that push/pull (e.g., drag) case unit(s) to andfrom the interface station(s). As another example, the pick head 4000A,4000B may be configured with a conveyor belt that conveys case unit(s)between the lift 150 and the interface station(s).

Referring now to FIGS. 2A, 3, 4A, and 4B, as noted above, the bot 110includes a transfer arm 110PA that effects the picking and placement ofcase units from the stacked storage spaces 130S, interface stations TSand peripheral buffer stations BS, BSD defined at least in part, in theZ direction) by one or more of the rails 1210A, 1210B, 1200 (FIG. 5A)(e.g. where the storage spaces, interface stations and/or peripheralbuffer stations may be further defined in the X and Y directions,relative to either of the rack frame of reference REF2 or the bot frameof reference REF, through the dynamic allocation of the case units asdescribed above). As may be realized, the bot defines the X transportaxis and, at least in part, the Y transport axis (e.g. relative to thebot frame of reference REF) as will be described further below. The bots110, as noted above, transport case units between each lift module 150and each storage space 130S on a respective storage level 130L.

The bots 110 include a frame 110F having a drive section 110DR and apayload section 110PL. The drive section 110DR includes one or moredrive wheel motors each connected to a respective drive wheel(s) 202 forpropelling the bot 110 along the X direction (relative to the bot frameof reference REF so as to define the X throughput axis). As may berealized, the X axis of bot travel is coincident with the storagelocations when the bot 110 travels through the picking aisles 130A. Inthis aspect the bot 110 includes two drive wheels 202 located onopposite sides of the bot 110 at end 110E1 (e.g. first longitudinal end)of the bot 110 for supporting the bot 110 on a suitable drive surfacehowever, in other aspects any suitable number of drive wheels areprovided on the bot 110. In one aspect each drive wheel 202 isindependently controlled so that the bot 110 may be steered through adifferential rotation of the drive wheels 202 while in other aspects therotation of the drive wheels 202 may be coupled so as to rotate atsubstantially the same speed. Any suitable wheels 201 are mounted to theframe on opposite sides of the bot 110 at end 110E2 (e.g. secondlongitudinal end) of the bot 110 for supporting the bot 110 on the drivesurface. In one aspect the wheels 201 are caster wheels that freelyrotate allowing the bot 110 to pivot through differential rotation ofthe drive wheels 202 for changing a travel direction of the bot 110. Inother aspects the wheels 201 are steerable wheels that turn undercontrol of, for example, a bot controller 110C (which is configured toeffect control of the bot 110 as described herein) for changing a traveldirection of the bot 110. In one aspect the bot 110 includes one or moreguide wheels 110GW located at, for example, one or more corners of theframe 110F. The guide wheels 110GW may interface with the storagestructure 130, such as with guide rails 1200S (FIG. 1C) within thepicking aisles 130A, on the transfer deck 130B and/or at interface ortransfer stations for interfacing with the lift modules 150 for guidingthe bot 110 and/or positioning the bot 110 a predetermined distance froma location to/from which one or more case units are placed and/or pickedup as described in, for example, U.S. patent application Ser. No.13/326,423 filed on Dec. 15, 2011 the disclosure of which isincorporated herein by reference in its entirety. As noted above, thebots 110 may enter the picking aisles 130A having different facingdirections for accessing storage spaces 130S located on both sides ofthe picking aisles 130A. For example, the bot 110 may enter a pickingaisle 130A with end 110E2 leading the direction of travel or the bot mayenter the picking aisle 130A with end 110E1 leading the direction oftravel.

The payload section 110PL of the bot 110 includes a payload bed 110PB, afence or datum member 110PF, a transfer arm 110PA and a pusher bar ormember 110PR. In one aspect the payload bed 110PB includes one or morerollers 110RL that are transversely mounted (e.g. relative to alongitudinal axis LX of the bot 110) to the frame 110F so that one ormore case units carried within the payload section 110PL can belongitudinally moved (e.g. justified with respect to a predeterminedlocation of the frame/payload section and/or a datum reference of one ormore case units) along the longitudinal axis of the bot, e.g., toposition the case unit at a predetermined position within the payloadsection 110PL and/or relative to other case units within the payloadsection 110PL (e.g. longitudinal forward/aft justification of caseunits). In one aspect the rollers 110RL may be driven (e.g. rotatedabout their respective axes) by any suitable motor for moving the caseunits within the payload section 110PL. In other aspects the bot 110includes one or more longitudinally movable pusher bar (not shown) forpushing the case units over the rollers 110RL for moving the caseunit(s) to the predetermined position within the payload section 110PL.The longitudinally movable pusher bar may be substantially similar tothat described in, for example, U.S. patent application Ser. No.13/326,952 filed on Dec. 15, 2011, the disclosure of which waspreviously incorporated by reference herein in its entirety. The pusherbar 110PR is movable in the Y direction, relative to the bot 110reference frame REF to effect, along with the fence 110PF and or pickhead 270 of the transfer arm 110PA, a lateral justification of caseunit(s) within the payload area 110PL in the manner described in U.S.Provisional Patent Application No. 62/107,135 filed on Jan. 23, 2015,previously incorporated herein by reference in their entireties.

Still referring to FIG. 6, the case units are placed on the payload bed110PB and removed from the payload bed 110PB with the transfer arm 110PAalong the Y transport axis. The transfer arm 110PA includes a liftmechanism or unit 200 located substantially within the payload section110PL as described in, for example, U.S. Provisional Patent ApplicationNo. 62/107,135 filed on Jan. 23, 2015, previously incorporated herein byreference in their entireties. The lift mechanism 200 provides bothgross and fine positioning of pickfaces carried by the bot 110 which areto be lifted vertically into position in the storage structure 130 forpicking and/or placing the pickfaces and/or individual case units to thestorage spaces 130S (e.g. on a respective storage level 130L on whichthe bot 110 is located). For example, the lift mechanism 200 providesfor picking and placing case units at the multiple elevated storageshelf levels 130LS1-130LS4, TL1, TL2 accessible from the common pickingaisle or interface station deck/rail 1200S (see e.g. FIGS. 1B and 5A).

The lift mechanism 200 is configured so that combined robot axis movesare performed (e.g. combined substantially simultaneous movement of thepusher bar 110PR, lift mechanism 200, pick head extension and fore/aftjustification mechanism(s) such as, e.g., the longitudinally movablepusher bar described above), so that different/multi-sku or multi-pickpayloads are handled by the bot. In one aspect, the actuation of thelifting mechanism 200 is independent of actuation of the pusher bar110PR as will be described below. The decoupling of the lift mechanism200 and pusher bar 110PR axes provides for combined pick/place sequenceseffecting a decreased pick/place cycle time, increased storage andretrieval system throughput and/or increased storage density of thestorage and retrieval system as described above. For example, the liftmechanism 200 provides for picking and placing case units at multipleelevated storage shelf levels accessible from a common picking aisleand/or interface station deck 1200S as described above.

The lifting mechanism may be configured in any suitable manner so that apick head 270 of the bot 110 bi-directionally moves along the Z axis(e.g. reciprocates in the Z direction—see FIG. 2A). In one aspect, thelifting mechanism includes a mast 200M and the pick head 270 is movablymounted to the mast 200M in any suitable manner. The mast is movablymounted to the frame in any suitable manner so as to be movable alongthe lateral axis LT of the bot 110 (e.g. in the Y direction so as todefine the Y transport axis). In one aspect the frame includes guiderails 210A, 210B to which the mast 200M is slidably mounted. A transferarm drive 250A, 250B may be mounted to the frame for effecting at leastmovement of the transfer arm 110PA along the lateral axis LT (e.g. Yaxis) and the Z axis. In one aspect the transfer arm drive 250A, 250Bincludes an extension motor 301 and a lift motor 302. The extensionmotor 301 may be mounted to the frame 110F and coupled to the mast 200Min any suitable manner such as by a belt and pulley transmission 260A, ascrew drive transmission (not shown) and/or a gear drive transmission(not shown). The lift motor 302 may be mounted to the mast 200M andcoupled to pick head 270 by any suitable transmission, such as by a beltand pulley transmission 271, a screw drive transmission (not shown)and/or a gear drive transmission (not shown). As an example, the mast200M includes guides, such as guide rails 280A, 280B, along which thepick head 270 is mounted for guided movement in the Z direction alongthe guide rails 280A, 280B. In other aspects the pick head is mounted tothe mast in any suitable manner for guided movement in the Z direction.With respect to the transmissions 271, a belt 271B of the belt andpulley transmission 271 is fixedly coupled to the pick head 270 so thatas the belt 271B moves (e.g. is driven by the motor 302) the pick head270 moves with the belt 271B and is bi-directionally driven along theguide rails 280A, 280B in the Z direction. As may be realized, where ascrew drive is employed to drive the pick head 270 in the Z direction, anut may be mounted to the pick head 270 so that as a screw is turned bythe motor 302 engagement between the nut and screw causes movement ofthe pick head 270. Similarly, where a gear drive transmission isemployed a rack and pinion or any other suitable gear drive may drivethe pick head 270 in the Z direction. In other aspects any suitablelinear actuators are used to move the pick head in the Z direction. Thetransmission 260A for the extension motor 301 is substantially similarto that described herein with respect to transmission 271.

Still referring to FIG. 2A the pick head 270 of the bot 110 transferscase units between the bot 110 and a case unit pick/place location suchas, for example, the storage spaces 130S, peripheral buffer stations BS,BSD and/or interface stations TS (see FIGS. 3, 4A, and 4B) and in otheraspects substantially directly between the bot 110 and a lift module(s)150. In one aspect, the pick head 270 includes a base member 272, one ormore tines or fingers 273A-273E and one or more actuators 274A, 274B.The base member 272 is mounted to the mast 200M, as described above, soas to ride along the guide rails 280A, 280B. The one or more tines273A-273E are mounted to the base member 272 at a proximate end of thetines 273A-273E so that a distal end of the tines 273A-273E (e.g. a freeend) is cantilevered from the base member 272. Referring again to FIG.1D, the tines 273A-273E are configured for insertion between slats 1210Sthat form the case unit support plane CUSP of the storage shelves.

One or more of the tines 273A-273E is movably mounted to the base member272 (such as on a slide/guide rail similar to that described above) soas to be movable in the Z direction. In one aspect any number of tinesare mounted to the base member 272 while in the aspect illustrated inthe figures there are, for example, five tines 273A-273E mounted to thebase member 272. Any number of the tines 273A-273E are movably mountedto the base member 272 while in the aspect illustrated in the figures,for example, the outermost (with respect to a centerline CL of the pickhead 270) tines 273A, 273E are movably mounted to the base member 272while the remaining tines 273B-273D are immovable relative to the basemember 272.

In this aspect the pick head 270 employs as few as three tines 273B-273Dto transfer smaller sized case units (and/or groups of case units) toand from the bot 110 and as many as five tines 273A-273E to transferlarger sized case units (and/or groups of case units) to and from thebot 110. In other aspects, less than three tines are employed (e.g. suchas where more than two tines are movably mounted to the base member 272)to transfer smaller sized case units. For example, in one aspect all butone tine 273A-273E is movably mounted to the base member so that thesmallest case unit being transferred to and from the bot 110 withoutdisturbing other case units on, for example, the storage shelves has awidth of about the distance X1 between slats 1210S (see FIG. 1D).

The immovable tines 373B-373D define a picking plane SP of the pick head270 and are used when transferring all sizes of case units (and/orpickfaces) while the movable tines 373A, 373E are selectively raised andlowered (e.g. in the Z direction with the actuators 274A, 274B) relativeto the immovable tines 373B-373D to transfer larger case units (and/orpickfaces). Still referring to FIG. 2A an example is shown where all ofthe tines 273A-273E are positioned so that a case unit support surfaceSF of each tine 273A-273E is coincident with the picking plane SP of thepick head 270 however, as may be realized, the two end tines 273A, 273Eare movable so as to be positioned lower (e.g. in the Z direction)relative to the other tines 273B-273D so that the case unit supportsurface SF of tines 273A, 273E is offset from (e.g. below) the pickingplane SP so that the tines 273A, 273E do not contact the one or morecase units carried by the pick head 270 and do not interfere with anyunpicked case units positioned in storage spaces 130S on the storageshelves or any other suitable case unit holding location.

The movement of the tines 273A-273E in the Z direction is effected bythe one or more actuators 274A, 274B mounted at any suitable location ofthe transfer arm 110PA. In one aspect, the one or more actuators 274A,274B are mounted to the base member 272 of the pick head 270. The one ormore actuators are any suitable actuators, such as linear actuators,capable of moving one or more tines 273A-273E in the Z direction. In theaspect illustrated in, for example, FIG. 2A there is one actuator 274A,274B for each of the movable tines 273A, 273E so that each moveable tineis independently movable in the Z direction. In other aspects oneactuator may be coupled to more than one movable tine so that the morethan one movable tine move as a unit in the Z direction.

As may be realized, movably mounting one or more tines 273A-273E on thebase member 272 of the pick head 270 provides for full support of largecase units and/or pickfaces on the pick head 270 while also providingthe ability to pick and place small case units without interfering withother case units positioned on, for example, the storage shelves,interface stations and/or peripheral buffer stations. The ability topick and place variably sized case units without interfering with othercase units on the storage shelves, interface stations and/or peripheralbuffer stations reduces a size of a gap GP (see FIG. 1B) between caseunits on the storage shelves. As may be realized, because the tines273B-273D are fixed to the base member 272 there is no duplicativemotion when picking/placing case units as the lifting and lowering ofcase units and/or pickfaces to and from the case unit holding locationis effected solely by the lift motor 301, 301A.

Referring again to FIG. 2A, it is again noted that the pusher bar 110PRis movable independent of the transfer arm 110PA. The pusher bar 110PRis movably mounted to the frame in any suitable manner such as by, forexample, a guide rod and slide arrangement and is actuated along the Ydirection (e.g. in a direction substantially parallel to theextension/retraction direction of the transfer arm 110PA). In one aspectat least one guide rod 360 is mounted within the payload section 110PLso as to extend transversely relative to the longitudinal axis LX of theframe 110F. The pusher bar 110PR may include at least one slide member360S configured to engage and slide along a respective guide rod 360. Inone aspect, at least the guide rod/slide arrangement holds the pusherbar 110PR captive within the payload section 110PL. The pusher bar 110PRis actuated by any suitable motor and transmission, such as by motor 303and transmission 303T. In one aspect the motor 303 is a rotary motor andthe transmission 303T is a belt and pulley transmission. In otheraspects the pusher bar 110PR may be actuated by a linear actuator havingsubstantially no rotary components.

The pusher bar 110PR is arranged within the payload section 110PL so asto be substantially perpendicular to the rollers 110RL and so that thepusher bar 110PR does not interfere with the pick head 270. As can beseen in FIG. 10B, the bot 110 is in a transport configuration where atleast one case unit would be supported on the rollers 110RL (e.g. therollers collectively form the payload bed). In the transportconfiguration the tines 273A-273E of the pick head 270 areinterdigitated with the rollers 110RL and are located below (along the Zdirection) a case unit support plane RSP of the rollers 110RL. Thepusher bar 110PR is configured with slots 351 into which the tines273A-273E pass where sufficient clearance is provided within the slots351 to allow the tines to move below the case unit support plane RSP andto allow free movement of the pusher bar 110PR without interference fromthe tines 273A-273E. The pusher bar 110PR also includes one or moreapertures through which the rollers 110RL pass where the apertures aresized to allow free rotation of the rollers about their respective axes.As may be realized, the independently operable pusher bar 110PR does notinterfere with the rollers 110RL, extension of the transfer arm 110PA inthe transverse direction (e.g. Y direction) and the lifting/lowering ofthe pick head 270.

As noted above, because the pusher bar 110PR is a separate, standaloneaxis of the bot 110 that operates free of interference from the pickhead 270 extension and lift axes, the pusher bar 110PR can be operatedsubstantially simultaneously with the lifting and/or extension of thetransfer arm 110PA. The combined axis moves (e.g. the simultaneousmovement of the pusher bar 110PR with the transfer arm 110PA extensionand/or lift axes) provides for increased payload handling throughput inalong the Y transport axis and effects the ordered (e.g. according to acase transfer sequence of the respective asynchronous level transportsystem 191) multi-pick of two or more case units from a common pickingaisle, in one common pass of the picking aisle as described in, forexample, U.S. Pat. No. 9,856,083 issued on Jan. 2, 2018, the disclosureof which was previously incorporated herein by reference in itsentirety.

Referring to FIGS. 1A and 5A, as noted above, the lifts 150 forming themore than one independent lift axis 150X1-150Xn is controlled by controlserver 120 so that when picking and placing case unit(s) the pick headis raised and/or lowered to a predetermined height corresponding to, forexample, an interface station TS at a predetermined storage level 130Land/or the traverse 550 (e.g., to at least in part resequence the mixedcases). In one aspect, the control server 120 also controls the traverse550 so that the traverse transfer case units, not only to the outputstation 160UT, but also between the more than one independent lift axis150X1-150Xn. Here the more than one independent lift axis 150X1-150Xnresequences inferior ordered sequence of mixed cases 170 alone or inconjunction with the traverse 550 in any suitable manner, such asdescribed below.

In one aspect, as described herein, the more than one lift axis150X1-150Xn forms a bypass or pass through (on the fly or in motus) inthe lift transport stream. As described herein, each level 130L of themulti-level transport system 190 has an asynchronous level transportsystem (where, e.g., asynchronous may refer to the bots 110 beingundeterministic, and, at least in part, the transfer deck 130B beingundeterministic so that each aisle/storage location communicates withthe input/output stations at each level 130L). Each asynchronous leveltransport system 191 has a level transport rate TXR (FIG. 1) that may beoptimized in any suitable manner for load balancing. The level transportrate TXR produces or otherwise defines load spreading so each bot 110may effect a similar number (e.g., average number) of transactions(e.g., moving cases from storage to the input/output stations). In otheraspects the level transport rate TXR may be time optimized to minimizetransaction time to and from the storage racks for one or more cases,via one or more bots 110/asynchronous level transport axes X, Y of atleast part of one or more asynchronous level transport system 191. Instill other aspects, the level transport rate TXR may be a combinationof load balancing and time optimization. As may be realized, the leveltransport rate TXR promotes a rate of optimization, for the asynchronouslevel transport system 191 (e.g., by load balancing and/or timeoptimization) over the sequence of mixed cases in the level transporttransactions. In one aspect, at least some sequencing may be performedby the asynchronous level transport system(s) 191 in a manner similar tothat described in, for example, United States pre-grant publicationnumber 2016/0207711 published on Jul. 21, 2016 (application Ser. No.14/997,902) and/or U.S. Pat. No. 9,850,079 issued on Dec. 26, 2017(application Ser. No. 15/003,983), the disclosures of which areincorporated herein by reference in their entireties; however, in otheraspects the sequencing of cases by the asynchronous level transportsystem(s) 191 may be a secondary consideration and be based on, forexample, opportunity via level transfer rate optimization. The leveltransport rate produces or otherwise defines the available sequence ofmixed cases (also referred to as the inferior ordered sequence of mixedcases 170) defined and effected by the level transport rate TXR at theinfeed interface 555, see, e.g., FIG. 7 and equation [1] below.

In one aspect, referring to FIGS. 1A, 5A, and 7, the control server 120may control the more than one lift axis 150X1-150Xn to sequence thecases (e.g., multi-lift case sequencing) so that the case units arepicked by the more than one lift axis 150X1-150Xn in an inferior manner,from any of level 130L of the multi-level transport system 190, wherethe case units are transported to the traverse 550 in the superiorordered sequence of mixed cases 171S. By way of example, the controlserver 120 may include a system model 128 and a state maintenance andestimation module 129 substantially similar to those described in U.S.Pat. No. 9,733,638 issued on Aug. 15, 2017 (application Ser. No.14/229,004) the disclosure of which is incorporated herein by referencein its entirety. The system model 128 may model performance aspects, andconstraints of components (e.g., the lift axes 150X1-150Xn, the storagestructure 130, bots 110, input and output stations, etc.) of the storageand retrieval system 100. The system model solution may explore statetrajectories for action, such as transportation of cases in an orderlist by the more than one lift axis 150X1-150Xn. The system model may beupdated, for example, via sensory and actuation data from lower levelcontrollers (see controllers 120S1-120Sn described herein), on asubstantially real time bases, enabling on the fly or in motusdetermination of optimum solutions over a predetermined time period. Thestate maintenance and estimation module 129 may be coupled to the statemodels and may facilitate estimation and maintenance of statetrajectories generated with the state model. The state trajectoryestimates this are dynamic and may account for uncertainty anddisturbances, changes in resources, objectives and/or constraints andmay be updated over a desired segment of the predetermined time periodaccording to various disturbances and/or triggers (e.g., recedingplanning horizon, level shutdown, bot failure, storage pick actionfailure, storage put/place action failure, etc.)

The case units are transferred to, for example, the transfer stations TSon one or more levels 130L by the respective asynchronous leveltransport system 191 in the infeed order sequence 173 so that the caseunits are disposed on at the transfer stations TS in the inferiorordered sequence of mixed cases 170. The case units may be transferredby the multi-level transport system 190 to the infeed of the lifttransport system 500 as a substantially continuous input stream of mixedcases, groups of mixed cases, pickfaces of mixed cases, etc. The infeedof the lift transport system 500 may be defined by an infeed interface555 frame 777 (FIG. 7) which may not necessarily be a physicalstructure; rather the infeed interface 555 frame 777 defines the outerbounds of the X (or Y) and Z range of the lift transport system 500within the storage and retrieval system 100. The more than oneindependent lift axis 150X1-150Xn utilize one or more of the transferstations TS (on the different levels 130L of the multi-level transportsystem 190), the buffer stations BS (on the different levels 130L of themulti-level transport system 190), and the traverse 550 (or othersuitable conveyor(s)) to transition the cases in/to the superior orderedsequence of mixed cases 171S.

The infeed interface 555 reference frame couples the “cell” 150CEL ofmore than one independent lift axis 150X1-150Xn (which are merged to acommon output 300 as described herein) with the multi-level transportsystem 190 and each of the asynchronous level transport systems 191 onthe different levels 130L so that each lift axis 150X1-150Xn has adifferent corresponding input/output station (e.g., also referred toherein as infeed stations 556) at each asynchronous level transportsystem 191 where the input/output station 556 form a multidimensionalarray I/O(x,z). The asynchronous level transport system 191 at itsoptimized transfer rate (of transactions) provides or inputs mixed casesat each of the array of input/output station 556 that, collectivelydefine, via each input/output station 556 in combination, an availableorder sequence of mixed cases (also referred to as the inferior orderedsequence of mixed cases 170 at the infeed interface 555 (andcorrespondingly at each input/output station 556). The available ordersequence of mixed cases 170 is thus determined by the level transporttransaction rate TXR and may be considered as a three-dimensional array,with two dimensionally distributed input/output stations 556 (e.g.distributed in x and z) and variable with time (t). The available ordersequence of mixed cases 170 may be characterized as I/O (x, z) (t).Further, for purposes of simplicity of the description, the infeedinterface 555 may be treated as a common aggregated infeed interface 555frame 777 (FIG. 7), the three-dimensional array being represented as asingle common linear input axis variable with time, wherein theavailable order sequence of mixed cases from the asynchronous leveltransport system(s) 191 at the infeed interface 555 may be characterizedas a normalized input α_(i), where α1, α2, α3, etc. are the order ofmixed cases as available at the infeed interface 555 frame 777. As notedbefore, the available order sequence of mixed cases 170 does notcorrelate with, or has a weak correlation to the predetermined ordersequence of predetermined case out order sequence of mixed cases 172.

The more than one independent lift axis 150X1-150Xn (e.g., a lift axissystem having more than one lift axis merged to the common output 300)feeds mixed cases, via the infeed interface 555 frame, at the availableorder sequence of mixed cases 170, and has a configuration that createsan ordered sequence of mixed cases 171 (that may be characterized asnormalized output Ω_(i)) at the common output 300 that conforms with orhas a strong correlation with the predetermined case out order sequenceof mixed cases 172. As described further below, each of the more thanone independent lift axis 150X1-150Xn is configured to define acorresponding pass through or bypass (also referred to as a switch)relative to another different one of the more than one independent liftaxis 150X1-150Xn.

In the aspects of the disclosed embodiment described herein, the infeedfeed rate (I_((x, z)α)(t)) to the lift transport system 500, at whichthe inferior ordered sequence of mixed cases 170 (α(t)) is supplied tothe output and resequencing section 199 by the a multi-level transportsystem 190, can be defined asI _((x,z)α)(t)=α(t)=α1,α2,α3,α4,α5, . . . ,αn  [1]

for any given predetermined period of time (e.g., horizon) where, α1through an represent ordinate case units, in a time ordered sequence ofcase units, that form the inferior ordered sequence of mixed cases 170(α(t)), transported to the lift transport system 500 by the multi-leveltransport system 190. For example, α1 is the first case unit to betransferred to the lift transport system 500, α2 is the second case unitto be transferred to the lift transport system 500, and so on. Inaddition, the “x” in equation 1 above may be changed to “y” or any othersuitable substantially horizontal axis identifier (e.g., as axissubstantially transverse to the transfer axis of the outbound lifts150B) along which the case units are being transferred.

The infeed feed rate I_((x, z)α)(t) is effected by the bots 110 of oneor more of the respective asynchronous level transport system 191 of thea multi-level transport system 190. For example, bot 110tasking/assignment may be optimized in a manner substantially similar tothat described in U.S. Pat. No. 9,733,638, issued on Aug. 15, 2017, thedisclosure of which is incorporated herein by reference in its entirety.As noted above, one or more of the component controllers 120S1-120Sn maymanage operation of the bots 110 of the respective asynchronous leveltransport system 191. The component controllers 12051-120Sn may have acontroller hierarchy where upper level component controllers generatedcommands for lower level controllers (e.g., such as controllers 110C ofthe bots 110) to perform actions that effect the task assigned to therespective upper level component controllers. As an example, one or moreof the component controllers 12051-120Sn may independently determine thebot 110 assignments that will handle and move the case unitscorresponding to the tasks assigned to the one or more of the componentcontrollers 12051-120Sn. The one or more of the component controllers12051-120Sn may also use model predictive control in determiningassignments for the bots 110. The one or more of the componentcontrollers 120S1-120Sn thus may be configured to solve a bot 110routing problem and may resolve traffic management and routingdestination to provide an optimal solution to bot 110 tasking. The oneor more of the component controllers 120S1-120Sn may select the optimalbot 110 from a number of selectable bots 110 of the respectiveasynchronous level transport system 191 and generate the bot assignmentto the task. The one or more of the component controllers 120S1-120Snassignments to the bots 110 (or bot controllers 110C) may determinedestination (e.g., the selected storage location of an ordered case unitaccording to the task assignment) and path for the bot 110 to move froman origin or initial location of the bot 110 on the level 130L to theassigned destination. In one aspect, the storage locations/spaces 130S(FIG. 1A) may be arrayed along storage/picking aisles 130A (FIG. 1A),that may be interconnected by transfer decks 130B (FIG. 1A) providingsubstantially open or undeterministic riding surfaces (or in otheraspects deterministic riding surfaces) as described herein. Accordinglymultiple paths may be available for the bot 110 to proceed from theorigin location (at the time of tasking) to the destination. The one ormore of the component controllers 120S1-120Sn may select the optimalpath for the given bot 110 and the problem of rover assignment androuting may be solved in a coordinated manner for all bots 110 of therespective asynchronous level transport system 191 over a predeterminedperiod of time. Each bot 110 assignment (destination and path) may thusbe optimized over the predetermined period of time (e.g. a timehorizon), and the controller solution may be dynamically updated fordesired time segments in the predetermined period of time to account forchanging conditions, objectives, resources, and parameters of the amulti-level transport system 190.

In the aspects of the disclosed embodiment described herein, thesuperior ordered sequence of mixed cases 171S which has a strongcorrelation to the predetermined case out order sequence of mixed cases172 (Ω(t)), and which is output at an output rate (R_(Ω)(t)) of the lifttransport system 500 can be defined asR _(Ω)(t)≅Ω(t)=Ω1,Ω2,Ω3,Ω4,Ω5, . . . ,Ωn  [2]

over any given period of time (e.g., horizon) where, Ω1 through Ωnrepresent ordinate case units in a time ordered sequence of case unitsoutput from the lift transport system 500 at the common output 300. Forexample, Ω1 is the first case unit to be output from the lift transportsystem 500, Ω2 is the second case unit to be output from the lifttransport system 500, and so on. Here the output rate R_(Ω)(t) of thelift transport system 500 is substantially equal to or greater than thetransaction rate of the high speed (over 500, and in one aspect over1000, transfer actions per hour on a pallet) pallet builder (e.g.,palletizer 160PB).

Also, in the aspects of the disclosed embodiment, Z_(x)(t) representsthe aggregate linearized stream (e.g., lift axis feed rate) of casesprocessed through the lift transport system 500. For example, the flowof case unit through the lift transport system may be a channelizedmulti-stream flow where each lift axis 150X1-150Xn is arranged (e.g.,the lift axes 150X1-150Xn form a cell of horizontally spread apart liftaxes) along the X (or Y) axis (e.g., in a reference frame of the storageand retrieval system 100—see, e.g., FIGS. 3, 4A, 7) outputs a stream(e.g., a Z axis stream of case units) of the multi-stream flow where theoutput of each stream is aggregated with at least another Z axis streamof another lift axis 150X1-150Xn and channelized into a linear stream ofcase units (e.g., representative of the superior ordered sequence ofmixed cases 171S (Ω(t)) by the common output 300 of the lift transportsystem 500. It is again noted that the “x” in the term Z_(x)(t) may bechanged to “y” or any other suitable substantially horizontal axisidentifier (e.g., as axis substantially transverse to the transfer axisof the outbound lifts 150B) along which the case units are beingtransferred. As can be seen in, e.g., FIG. 3 (with respect to the commonoutputs 300′), 4A, and 4B (with respect to the individual stream of caseunits from the respective traverses 550 arranged in parallel) the Z axisstreams may be aggregated along parallel paths to the common output 300;and/or in other aspects, as can be seen in, e.g., FIG. 3 (with respectto traverse 550), FIG. 4B (with respect to the aggregation of case unitson the individual traverses 550). 5A, 6A, and 6B the Z axis streams maybe aggregated along a common path to the common output 300.

The lift axis feed rate Z_(x)(t) may be a substantially constant feedrate that is substantially the same as the output rate R_(Ω)(t) of thelift transport system 500. In some aspects, the lift axis feed rateZ_(x)(t) may be effected by one or more bypass switches δ1-δn (see,e.g., δ1, δ2, δ3 in FIG. 7, however any suitable number of bypassswitches may be provided) whereα(t)+δ(t)≅Ω(t)

and δ(t) is a bypass switch rate for any given period of time (e.g.horizon), and where α(t) is not equal to Ω(t). The output rate R_(Ω)(t)of the lift transport system 500 may be a time optimal output rate whereeach lift axis 150X1-150Xn picks case units from each level 130L in anorder of availability of the case units (e.g., the availability of caseunits being effected by the infeed feed rate I_((x, z)α)(t)/inferiorordered sequence of mixed cases 170 (α(t)) where the order in which thecase units are picks is decoupled from the superior ordered sequence ofmixed cases 171S (Ω(t)).

Still referring to FIG. 7, as noted above, the lifting transport systemincludes one or more bypass switches δ1-δn. As will be described below,in one aspect, the one or more bypass switches δ1-δn may be effectedwith a lift axis 150X1-150Xn alone (e.g., the lift transport rate LRT issubstantially equal to the bypass δ_(j)—see for example, switch δ2 in,e.g., FIG. 7 where α4 is to precede α3 in the superior ordered sequenceof mixed cases 171S (Ω(t)) where the order is Ω3, Ω4, etc.). In yetanother aspect, the one or more bypass switches δ1-δn may be effectedwith a lift axis 150X1-150Xn and a traverser 550 (e.g., the lifttransfer rate LRT and the traverser travel or swap time is substantiallyequal to the bypass δ_(j)—see for example, switch δ1 in, e.g., FIG. 7where α2 is to precede α1 in the superior ordered sequence of mixedcases 171S (Ω(t)) where the order is Ω1, Ω2, etc.). In still anotheraspect, the one or more bypass switches δ1-δn may be effected with alift axis 150X1-150Xn and a lift pick and place (e.g., the lift transferrate LRT and the pick place transaction rate TRT is substantially equalto the bypass δ_(j)—see for example, switches δ4-δ6 in, e.g., FIG. 7A).In yet another aspect, the one or more bypass switches δ1-δn may beeffected with a lift axis 150X1-150Xn, a lift pick and place, and atraverser 550 (e.g., the lift transfer rate LRT, the pick placetransaction rate TRT, and the traverser travel or swap time issubstantially equal to the bypass δ_(j)—see for example, switch δ1 in,e.g., FIG. 7 where α6 is to precede α5 in the superior ordered sequenceof mixed cases 171S (Ω(t)) where the order is Ω5, Ω6, etc.). In a pickand place operation of the lift axis 150X1-150Xn, a case unit is pickedfrom one station 556 and placed at another station 556 along a commonlift axis (as shown in FIG. 10) or on a traverser 550, and/or pickedfrom one traverser 550A and placed on another traverser 550B (e.g., sothat a transfer time of one case is increased so that other cases can beoutput with a higher priority). Referring also to FIG. 7A, in oneaspect, the lifts 150 (lifts 150X1 is shown for exemplary purposes only)may be configured to bi-directionally extend in direction 4050 forpicking and placing case units to opposite sides of the lift 150X1. Forexample, the lift 150X1 may have a first side on which infeed stations556A-556C are located and an opposite side on which infeed stations556D-556F are located. The lift load handling device LHD is configuredto bi-directionally extend in direction 4050 for accessing each of theinfeed stations 556A-556F. Here bypass switch δ4 formed by the at leastone lift axis crosses the lift axis from one side to another side (e.g.,a case unit is transferred between opposing infeed stations such asinfeed stations 556A, 556D on a common level 130L1). Here the bypassswitch δ4 swaps cases from side to side on a common level. In anotheraspect, bypass switch δ5 formed by the at least one lift axis crossesthe lift axis from one side to another side and has a portion of thebypass path that extends along the lift axis and a level travel portionthat extend in a plane of a respective level (e.g., a case unit istransferred between opposing infeed stations such as infeed stations556B, 556D on different levels 130L1, 130L2). Here the bypass switch δ5swaps cases from side to side on different levels. In yet anotheraspect, bypass switch δ6 formed by the at least one lift axis has atleast a bypass path portion extending along the lift axis and a leveltravel portion (e.g., a case unit is transferred between infeed stationssuch as infeed stations 556D, 556F on a common side of the lift axis150X1. Here the bypass switch δ6 swaps cases to different levels on asame side of the lift axis (as may be realized bi-directional extensioncapabilities are not necessary to effect bypass switch δ6). In otheraspects, the switches δ1-δn may be used in any suitable combinationthereof to prioritize the output of case units. The one or more bypassswitches δ1-δn provide the respective lift axis 150X1-150Xn with a passthrough Z axis stream of case units where the pass through, as will bedescribed herein, is effected with the respective lift axis 150X1-150Xnalone or with the respective lift axis 150X1-150Xn and the traverse 550.The one or more bypass switches δ1-δn operate so as to maintain the timeoptimal output rate of R_(Ω)(t) of the lift transport system 500. Forexample, in a manner similar to that described above with respect to thebots 110, one or more of the component controllers 120S1-120Sn maymanage operation of the lift axes 150X1-150Xn of a respective lifttransport system 500. The component controllers 120S1-120Sn may have acontroller hierarchy where upper level component controllers generatecommands for lower level controllers (e.g., such as controllers 150CNTof the lifts 150B) to perform actions that effect the task assigned tothe respective upper level component controllers. As an example, one ormore of the component controllers 120S1-120Sn may independentlydetermine the lift axis 150X1-150Xn assignments that will handle andmove the case units corresponding to the tasks assigned to the one ormore of the component controllers 120S1-120Sn. The one or more of thecomponent controllers 120S1-120Sn may also use model predictive controlin determining assignments for the lift axes 150X1-150Xn. The one ormore of the component controllers 120S1-120Sn thus may be configured tosolve a case unit transport problem, as described above, from the commoninfeed interface 555 frame 777 to the common output 300 for resequencingthe case units from the inferior ordered sequence of mixed cases 170(α(t)) to the superior ordered sequence of mixed cases 171S (Ω(t)). Assuch, the one or more of the component controllers 120S1-120Sn mayresolve case unit traffic management over the lift axes 150X1-150Xn withthe one or more bypass switches δ1-δn and route case units through thelift transport system 500 to provide an optimal solution to lift axis150X1-150Xn tasking. The one or more of the component controllers120S1-120Sn assignments to the lift axes 150X1-150Xn (or liftcontrollers 150CNT) may determine destination (e.g., e.g., a temporarystorage location on another level 130L of the same or a different liftaxis or on the traverse 550) and as a result a path for the case unit tomove from an origin or initial location of the case unit on the infeedinterface 555 frame 777 to the assigned temporary storage locationand/or to the common output 300.

In one aspect, the temporary storage locations on the different levels130L of the different lift axes 150X1-150X effected by the one or morebypass switches δ1-δn may provide multiple paths for case unit transferthe origin location (at the time of tasking) to the common output 300.The one or more of the component controllers 120S1-120Sn may select theoptimal path for the given case unit and the problem of lift axisassignment and routing may be solved in a coordinated manner for alllift axis 150X1-150Xn of the respective lift transport system 500 over apredetermined period of time. Each lift axis 150X1-150Xn assignment(case unit destination and path) may thus be optimized over thepredetermined period of time (e.g. a time horizon), and the controllersolution may be dynamically updated for desired time segments in thepredetermined period of time to account for changing conditions,objectives, resources, and parameters of the lift transport system 500.Here each outbound lift 150B (e.g., the independent lift axes150X1-150Xn) pick case units from each level 130L in a manner that isdecoupled from the final predetermined case out ordered sequence, whichis substantially the same as the superior ordered sequence of mixedcases 171S (Ω(t)). As such, each outbound lift 150B (e.g., theindependent lift aces 150X1-150Xn) is free to pick case units from eachlevel in the order the case units become available.

As an illustrative example, FIG. 7 shows an exemplary lift transportsystem 500 having two lift axes 150X1, 150X2 spaced apart from eachother along, e.g., the X (or Y) axis of the storage and retrieval system100. In FIG. 7, case units are supplied to the infeed interface 555frame 777 on the different levels 130L at the infeed feed rateI_((x, z)α)(t) in the inferior ordered sequence of mixed cases 170(α(t)). As can be seen in FIG. 7, ordinate case unit 2 (Ω2) in thesuperior ordered sequence of mixed cases 171S (Ω(t) is the first caseunit to arrive at the infeed interface 555 frame 777 at lift axis 150X2.Ordinate case unit 1 (Ω1) in the superior ordered sequence of mixedcases 171S (Ω(t) is the second case unit to arrive at the infeedinterface 555 frame 777 at lift axis 150X1. Ordinate case unit 5 (Ω5) inthe superior ordered sequence of mixed cases 171S (Ω(t)) is the thirdcase unit to arrive at the infeed interface 555 frame 777 at lift axis150X1. Ordinate case unit (Ω3) in the superior ordered sequence of mixedcases 171S (Ω(t) is the fourth case unit to arrive at the infeedinterface 555 frame 777 at lift axis 150X2. Ordinate case unit 4 (Ω4) inthe superior ordered sequence of mixed cases 171S (Ω(t) is the fifthcase unit to arrive at the infeed interface 555 frame 777 at lift axis150X1. The arrival sequence of case units illustrated in FIG. 7 is notlimited to five case units (there may be more or less than five) and theorder of arrival of the case units is merely exemplary (the case unitsmay arrive in any order and at any lift axis).

The lift axes 150X1 and 150X2 and/or the traverse 550 are controlled asdescribed herein to transfer the case units Ω1-Ωn to the common output600 in the superior ordered sequence of mixed cases 171S (Ω(t)). As willbe described in greater detail herein, the one or more bypass switchesδ1-δn and/or the traverse 550 may be used to temporarily store or bufferone of more of the case units Ω1-Ωn at a different location of the lifttransport system 500 other than the respective origin location to effectresequencing of the case units to the superior ordered sequence of mixedcases 171S (Ω(t)). In one aspect, the traverse 550 may be bidirectionalto effect the buffering of the case units with the one or more bypassswitches δ1-δn. In one aspect, the traverse 550 may include dualtransport paths 550A, 550B (FIG. 7) where the dual transport paths(e.g., dual traversers) 550A, 550B provide for travel of the case unitsin opposite directions along the X (or Y) axis to effect buffering ofthe case units Ω1-Ωn along any lift axis 150X1-150Xn of the lifttransport system 500 and/or buffering the case units on the traverser550 itself while providing a substantially non-stop transport of caseunits Ω1-Ωn to the common output 300. In one aspect, the dual transportpaths 550A, 550B may be vertically offset from each other or disposed ina common (e.g., the same) vertical plane.

FIGS. 8 and 8A-8C illustrate one example of multi-lift case sequencing.FIG. 8 is representative of what is illustrated in FIGS. 8A-8C andillustrates in a two-dimensional plane the transfer of case units fromthe different levels 130L (level 1 to level n) of the common infeedinterface 555 frame 777 formed by lift axes 150X1-150Xn. Forillustrative purposes only, the case units being transferred to thecommon output 300 are at least case units C1-C4 (which can also bereferred to as Ω1-Ω4). Case units labeled FL are not yet beingtransferred by occupy a lift axis transfer location at a respectivelevel 130L. Here lift axes 150X1-150Xn transfer case units to thetraverse 550 so that the case units are in the order C1, C2, C3, C4corresponding to the superior ordered sequence of mixed cases 171S. Asdescribed above, the transfer of the case units from the respective liftaxis 150X1-150Xn to the traverse 550 may be along parallel transportpaths disposed between the lift axes 150X1 and the traverse 550 and/orthe case units may be placed on the traverse 550 by the respective liftaxis 150X1-150Xn.

FIGS. 8A-8C four independent lift axes 150X1-150X4 are illustrated forexemplary purposes only but in other aspects any suitable number ofindependent lift axes may be employed. Also, the resequencing of mixedcases will be described with respect to cases C1-C5 but in other aspectsany suitable number of cases may be resequenced and output from thelifting transport system 500. Here each case C1-C5 ordinate is uniquewithin the predetermined case out order sequence of mixed cases 172(FIG. 1A), which is this example is C1, C2, C3, C4, C5, and thus, withinthe superior ordered sequence of mixed cases 171S (FIG. 1A) at thecommon output 300 of the lifting transport system 500; though eachdifferent unique case ordinate may include one or more cases of whichone or more may be common cases to other different case ordinates.

As described herein, the more than one independent lift axes 150X1-150Xn(in this example, 150X1-150X4) have a configuration that resequences onthe fly (or in motus) so that the output ordered sequence improves(e.g., there is a superior change in mixed case order compared to theinferior ordered sequence of mixed cases 170 input to the liftingtransport system 500) regardless of input to the lifting transportsystem 500, and hence decouples the lifting transport system 500 outputfrom the lifting transport system 500 input. As such, the liftingtransport system 500 is configured to decouple bot(s) 110, from specificcase(s) transfer to the lifts 150B1-150B4.

Here, the bots 110 of the respective asynchronous level transport system191 input mixed case units to the lifting transport system 500 in theinferior ordered sequence of mixed cases 170 (FIG. 9, Block 800), suchas by placing the case units C1-C5 on, e.g., transfer shelves TS in anysuitable manner and in any suitable order, as noted herein. For example,case C2 is placed on level 130L4 at a transfer station corresponding tolift axis 150X1; case C1 is placed on level 130L3 at a transfer stationcorresponding to lift axis 150X2; case C5 is placed on level 130L3 at atransfer station corresponding to lift axis 150X3; case C4 is placed onlevel 130L1 at a transfer station corresponding to lift axis 150X2; andcase C3 is placed on level 130L4 at a transfer station corresponding tolift axis 150X4. One or more lift axes 150X1-150X4 transfer andresequence the input mixed case units to the common output 300 in thesuperior ordered sequence of mixed cases 171S (FIG. 9, Block 810)according to the case out ordered sequence of mixed cases 172. In thisexample, lift axis 150X2 transfers case C1 from the transfer station TSon level 130L3 to the traverse 550. Lift axis 150X1 transfers case C2from the transfer station TS on level 130L4 to the traverse 550, wherecase units C1 and C2 are placed on and travel along the traverse 550 soas to be in the ordered sequence C1, C2 (see FIG. 8B). Lift axis 150X4transfers case C3 from the transfer station TS on level 130L4 to thetraverse 550 so that case C3 follows case C2 in the ordered sequence.Lift axis 150X2 transfers case C4 from the transfer station TS on level130L1 to the traverse 550 so that case C4 follows case C3; and lift axis150X3 transfers case C5 from the transfer station TS on level 130L3 tothe traverse 550 so that case C5 follows case C4 (see FIG. 8C). As maybe realized, the case transfer and resequencing may continue with anylift axis(es) for any suitable number of cases to deliver the cases tothe common output 300 in the superior order sequence of mixed cases 171that has an improved sequence order (with respect to the case outordered sequence of mixed cases 172) when compared with the inferiorordered sequence of mixed cases 170.

FIGS. 10 and 10A-10C illustrate another example of multi-lift casesequencing. FIG. 10 is representative of what is illustrated in FIGS.10A-10C and illustrates in a two-dimensional plane the transfer of caseunits from the different levels 130L (level 1 to level n) of the commoninfeed interface 555 frame 777 formed by lift axes 150X1-150Xn with casebuffering, by one or more lift axis 150X1-150Xn, between storage levels130L so that the mixed cases output from by the lifting transport system500 are resequenced and transported to the common output 300. Here atleast one lift axis 150X1-150Xn defines a lift axis shunt or lift axisbypass path that stages (e.g., temporarily stores) case units ondifferent transfer/buffer shelves or suitable conveyors to improve theordered sequence of cases output from the lifting transport system 500.

In FIG. 10, and for illustrative purposes only, the case units beingtransferred to the common output 300 are at least case units C1-C4(which can also be referred to as Ω1-Ω4). Case units labeled FL are notyet being transferred by occupy a lift axis transfer location at arespective level 130L. As can be seen in FIG. 10, case unit C3 and caseunit C1 are arriving at the common infeed interface 555 frame 777 on thesame level 130L (e.g., level n) and at the same lift axis 150X2. Herecase unit C3 arrives before case unit C1; however, case unit C1 comesbefore case unit C3 in the ordered sequence of cases output from thelifting transport system 500. Here, lift axis 150X2 is controlled toremove case unit C3 from level n and place case unit C3 at an emptystorage location at level 2 along the lift axis 150X2 so that case unitC1 is accessible. The lift axes 150X1-150Xn are controlled, as describedabove, to transfer the case units C1-C4 to the common output so that thecase units are in the superior order sequence of mixed cases 171 at thecommon output 300. Again, the transfer of the case units from therespective lift axis 150X1-150Xn to the traverse 550 may be alongparallel transport paths disposed between the lift axes 150X1 and thetraverse 550 and/or the case units may be placed on the traverse 550 bythe respective lift axis 150X1-150Xn.

In the example illustrated in FIGS. 10A-10C, the case units aretransported and input to the lifting transport system 500 in a mannersubstantially similar to that described above (FIG. 11, Block 1000).Here, case C4 is placed on level 130L1 at a transfer station TScorresponding to lift axis 150X1; case C5 is placed on level 130L4 at atransfer station TS corresponding to lift axis 150X2; case C2 is placedon level 130L3 at a transfer station TS corresponding to lift axis150X3; and case C3 is placed on level 130L2 at a transfer station TScorresponding to lift axis 150X4. In this example, case C1 is input tothe lifting transport system 500 behind case C5 on level 130L4 at abuffer station BS corresponding to lift axis 150X2 where case C5 isblocking placement of case C1 onto the traverse 550.

Case C5 is moved by lift axis 150X2 to a transfer station TS/bufferstation BS or conveyor on another level (in this example, case C5 isstaged on level 130L3—see FIG. 10B) that corresponds with the lift axis150X2 so that a “hole is made” in the inferior ordered sequence of mixedcases 170 input to the lifting transport system 500 and a higherordinate case(s) (in this example, case C1) in the superior orderedsequence of mixed cases 171S become(s) accessible to the respective liftaxis 150X2 (FIG. 11, Block 1010). With case C5 staged on level 130L3,the lift axis 150X2 can remove case C1 from the transfer shelf TS orbuffer shelf BS on level 130L4 and transfer/resequence case C1 to thetraverse 550 (FIG. 10B; FIG. 11, Block 1020). In a manner similar tothat described above, case units C2-C5 are resequenced and transferredto the traverse 550, by their respective lift axis 150X1-150X4, to thecommon output 300 in the superior ordered sequence of mixed cases 171S(FIG. 11, Block 1020).

FIGS. 12 and 12A-12C illustrate yet another example of multi-lift casesequencing. FIG. 12 is representative of what is illustrated in FIGS.12A-12C and illustrates in a two-dimensional plane the transfer of caseunits from the different levels 130L (level 1 to level n) of the commoninfeed interface 555 frame 777 formed by lift axes 150X1-150Xn with casebuffering, between two or more lift axes 150X1-150Xn, and betweenstorage levels 130L so that the mixed cases output from by the liftingtransport system 500 are resequenced and transported to the commonoutput 300. In this example, the traverse 550 provides a lift axis shuntor lift axis bypass, where case(s) are transported along the traverse550 to open lift axis positions and are staged at any lift level (by arespective lift axis) to improve the output sequence of mixed casesoutput from the lifting transport system 500. In a manner similar tothat described above, at least one lift axis 150X1-150Xn may also definea lift axis shunt or lift axis bypass path that stages case units ondifferent transfer/buffer shelves or suitable conveyors to improve theordered sequence of cases output from the lifting transport system 500.

In FIG. 12, and for illustrative purposes only, the case units beingtransferred to the common output 300 are at least case units C1-C4(which can also be referred to as Ω1-Ω4). Case units labeled FL are notyet being transferred by occupy a lift axis transfer location at arespective level 130L. As can be seen in FIG. 12, case unit C3 and caseunit C1 are arriving at the common infeed interface 555 frame 777 on thesame level 130L (e.g., level n) and at the same lift axis 150X2. Herecase unit C3 arrives before case unit C1; however, case unit C1 comesbefore case unit C3 in the ordered sequence of cases output from thelifting transport system 500. Lift axis 150X2 is controlled to removecase unit C3 from level n and place case unit C3 on the traverse 550 fortransfer to lift axis 150X1 so that case unit C1 is accessible. Liftaxis 150X1 is controlled to remove case unit C3 from the traverse 550and place case units C3 in an empty storage location at level 2 alongthe lift axis 150X1. The lift axes 150X1-150Xn are controlled, asdescribed above, to transfer the case units C1-C4 to the common outputso that the case units are in the superior order sequence of mixed cases171 at the common output 300. Again, the transfer of the case units fromthe respective lift axis 150X1-150Xn to the traverse 550 may be alongparallel transport paths disposed between the lift axes 150X1 and thetraverse 550 and/or the case units may be placed on the traverse 550 bythe respective lift axis 150X1-150Xn.

In the example illustrated in FIGS. 12A-12C, the case units aretransported and input to the lifting transport system 500 in a mannersubstantially similar to that described above (FIG. 13, Block 12000).Here, case C4 is placed on level 130L1 at a transfer station TScorresponding to lift axis 150X1; case C5 is placed on level 130L4 at atransfer station TS corresponding to lift axis 150X2; case C2 is placedon level 130L1 at a transfer station TS corresponding to lift axis150X2; case C1 is placed on level 130L5 at a transfer station TScorresponding to lift axis 150X3; and case C3 is placed on level 130L3at a transfer station corresponding to lift axis 150X4. In this example,one or more case unit(s) are transferred to the traverse 550 by one ormore lift axes 150X1-150Xn for transfer to and staging along anotherlift axis 150X1-150Xn (FIG. 13, Block 12100). For example, lift axis150X2 picks case C5 from the transfer station TS on level 130L4 andplaces case C5 on the traverse 550. The traverse 550 transports case C5to any other suitable lift axis 150X1-150Xn for staging along therespective lift axis 150X1-150Xn to improve the ordered sequence ofcases output from the lifting transport system 500 (FIG. 12A). Forpurposes of illustration only, traverse 550 transports case C5 to liftaxis 150X4, where the lift axis 150X4 picks case C5 from the traverse550 and stages case C5 at, for example, level 130L2 of lift axis 150X4(FIG. 12B). In other aspects, case units may be transferred along acommon lift axis for staging in the manner described above with respectto FIGS. 10A-10C (FIG. 13, Block 12200).

The case units (pre or post staging) are transferred and resequenced tothe common output in the superior ordered sequence (FIG. 13, Block12300). For example, case C1 is transferred to the traverse 550 fromlevel 130L5 by lift axis 150X3; and case C2 is transferred to thetraverse 550 from level 130L1 (FIG. 12B), where case units C1 and C2 areplaced on the traverse 550 so as to be in the superior ordered sequenceof mixed cases 171S. Case C3 is transferred from level 130L3 along liftaxis 150X4 for placement on traverse 550 and case C4 is transferred fromlevel 130L1 along lift axis 150X1 for placement on traverse 550, where,as above, case units C3 and C4 are placed on the traverse 550 so as tobe in the superior ordered sequence of mixed cases 171S. Case C5 istransferred from level 130L2 along lift axis 150X4 for placement ontraverse 550 following case C4.

Referring now to FIGS. 1A and 15 an exemplary product order fulfillmentmethod will be described. The multi-level transport system 190 isprovided (FIG. 15, Block 15000), where, as described above, each level130L thereof has a corresponding independent asynchronous leveltransport system 191, of mixed cases, separate and distinct from theasynchronous level transport system 191 corresponding to each otherlevel 130L of the multi-level transport system 190. The liftingtransport system 500 is provided (FIG. 15, Block 15005) and includes, asdescribed above, the more than one independent lift axis 150X1-150Xn. Anordered sequence of mixed cases is created, with the more than oneindependent lift axes 150X1-150Xn, in accordance to a predetermined caseout ordered sequence of mixed cases 172 (FIG. 15, Block 15010), whereeach independent lift axis 150X1-150Xn is communicably coupled to eachother independent lift axis 150X1-150Xn of the more than one lift axis150X1-150Xn and forms the common output 300 of mixed cases output byeach of the more than one independent lift axis 150X1-150Xn. In creatingthe ordered sequence of mixed cases 171 the mixed cases are resequenced,as described above, effecting a change in the ordered sequence of themixed cases, with the lifting transport system 500 on the fly or inmotus, at infeed of the lifting transport system 500, to the superiorordered sequence of mixed cases 171S at the output of the liftingtransport system 500.

Creating the ordered sequence of mixed cases 171 may also includeforming a bypass path, as described above, with the traverse 550. In oneaspect, forming a bypass path, effects resequencing, at least in part,from an inferior ordered sequence of mixed cases 170, at infeed of thelifting transport system 500, to the superior ordered sequence of mixedcases 171S, at output of the lifting transport system, the inferiorordered sequence of mixed cases 170 and superior ordered sequence ofmixed cases 171S respectively being of inferior sequencing in sequenceorder and superior sequencing in sequence order relative to thepredetermined case out ordered sequence of mixed cases 172. In anotheraspect, forming a bypass path effects resequencing, at least in part,from the inferior ordered sequence of mixed cases 170, at infeed of thelifting transport system, to the superior ordered sequence of mixedcases 171S, at output of the lifting transport system 500, the inferiorordered sequence of mixed cases 170 and superior ordered sequence ofmixed cases 171S respectively being of inferior sequencing in sequenceorder and superior sequencing in sequence order relative to thepredetermined case out ordered sequence of mixed cases 172.

Referring now to FIGS. 1A and 16 an exemplary product order fulfillmentmethod will be described. The multi-level transport system 190 isprovided (FIG. 16, Block 16000), where, as described above, each level130L thereof has a corresponding independent asynchronous leveltransport system 191, of mixed cases, separate and distinct from theasynchronous level transport system 191 corresponding to each otherlevel 130L of the multi-level transport system 190. The liftingtransport system 500 is provided (FIG. 16, Block 16005) and includes, asdescribed above, the more than one independent lift axis 150X1-150Xn. Aninfeed interface 555 is provided (FIG. 16, Block 16010) and communicablycouples the multi-level transport system with each of the more than oneindependent lift axis 150X1-150Xn, where, as described above, the infeedinterface 555 includes different infeed stations 556 distributed at eachasynchronous level transport system 191 for each of the more than oneindependent lift axis 150X1-150Xn so that each of the more than oneindependent lift axis 150X1-150Xn has a different corresponding infeedstation 556 at each asynchronous level transport system 191 throughwhich mixed cases feed from the multi-level transport system 190 to eachof the more than one independent lift axis 150X1-150Xn.

Mixed cases are output substantially continuously through the commonoutput 300 (FIG. 16, Block 16015), with the more than one independentlift axis 150X1-150Xn, so as to output the mixed cases in apredetermined case out ordered sequence of mixed cases 172 decoupledfrom an available sequence of mixed cases 170 from and created by themulti-level transport system 190 at the infeed interface 555 and thatfeed the more than one independent lift axis 150X1-150Xn through theinfeed interface 555. In one aspect, outputting the mixed cases includescreating, with the more than one independent lift axis 150X1-150Xn ofthe lifting transport system 500, a lift transport stream 999 of mixedcases from the infeed interface 555 as described above. In creating thelift transport stream 999 the mixed cases are resequenced, as describedabove, effecting a change in the ordered sequence of the mixed cases,with the lifting transport system 500 on the fly or in motus, at infeedof the lifting transport system 500, to the superior ordered sequence ofmixed cases 171S at the output of the lifting transport system 500.

Creating the lift transport stream 999 may also include forming a bypasspath, as described above, with the traverse 550. In one aspect, forminga bypass path, effects resequencing, at least in part, from an inferiorordered sequence of mixed cases 170, at infeed of the lifting transportsystem 500, to the superior ordered sequence of mixed cases 171S, atoutput of the lifting transport system, the inferior ordered sequence ofmixed cases 170 and superior ordered sequence of mixed cases 171Srespectively being of inferior sequencing in sequence order and superiorsequencing in sequence order relative to the predetermined case outordered sequence of mixed cases 172. In another aspect, forming a bypasspath effects resequencing, at least in part, from the inferior orderedsequence of mixed cases 170, at infeed of the lifting transport system,to the superior ordered sequence of mixed cases 171S, at output of thelifting transport system 500, the inferior ordered sequence of mixedcases 170 and superior ordered sequence of mixed cases 171S respectivelybeing of inferior sequencing in sequence order and superior sequencingin sequence order relative to the predetermined case out orderedsequence of mixed cases 172.

In accordance with one or more aspects of the disclosed embodiment aproduct order fulfillment system comprises:

a multi-level transport system, each level thereof having acorresponding independent asynchronous level transport system, of mixedcases, separate and distinct from the asynchronous level transportsystem corresponding to each other level of the multi-level transportsystem, the asynchronous level transport system defining an array ofasynchronous level transport axes, corresponding to the level, and beingconfigured to hold and asynchronously transport at least one caseproviding transport of mixed cases along the array of asynchronous leveltransport axes; and

a lifting transport system with more than one independent lift axis,each of the more than one independent lift axis being configured toindependently hold the at least one case and reciprocate along a lifttravel axis independently raising and lowering the at least one caseproviding lifting transport of mixed cases between more than one of thelevels of the multi-level transport system, each independent lift axisbeing communicably coupled to each asynchronous level transport systemso as to provide for exchange of the at least one case between eachasynchronous level transport system and each independent lift axis, andmixed cases transferred from at least one asynchronous level transportsystem infeed to each of the more than one independent lift axis so thatmixed cases are output by the independent lift axis from the multi-leveltransport system;

wherein each independent lift axis, of the more than one lift axis, iscommunicably coupled to each other independent lift axis of the morethan one lift axis and forms a common output of mixed cases output byeach of the more than one independent lift axis, and the more than oneindependent lift axis are configured so as to create, at and from thecommon output, an ordered sequence of mixed cases in accordance to apredetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment, themore than one independent lift axis form an array of lift axes arrayedin at least one direction.

In accordance with one or more aspects of the disclosed embodiment, themore than one independent lift axis form an array of lift axes arrayedin more than one direction.

In accordance with one or more aspects of the disclosed embodiment themore than one independent lift axis are configured so as to resequencethe mixed cases and effect a change in the ordered sequence of the mixedcases, with the lifting transport system in motus, from an inferiorordered sequence of mixed cases, at infeed of the lifting transportsystem, to a superior ordered sequence of mixed cases, at output of thelifting transport system, the inferior ordered sequence and superiorordered sequence respectively being of inferior sequencing in sequenceorder and superior sequencing in sequence order relative to thepredetermined case out ordered sequence.

In accordance with one or more aspects of the disclosed embodiment thesuperior ordered sequence is characterized by its sequence order ofmixed cases that converges with the predetermined case out orderedsequence so that there is a strong correlation between respectivesequence orders of the superior ordered sequence and the predeterminedcase out ordered sequence, and wherein the inferior ordered sequence ischaracterized by its sequence order of mixed cases that diverges from oris substantially neutral to the predetermined case out ordered sequenceso that there is a weak correlation between respective sequence ordersof the inferior ordered sequence and the predetermined case out orderedsequence.

In accordance with one or more aspects of the disclosed embodiment thestrong correlation is such that the sequence order is a near netsequence order to that of the predetermined case out ordered sequence ofmixed cases.

In accordance with one or more aspects of the disclosed embodiment eachof the more than one independent lift axis is communicably coupled toeach asynchronous level transport axis of the array of asynchronouslevel transport axes corresponding to each asynchronous level transportsystem.

In accordance with one or more aspects of the disclosed embodiment eachof the more than one independent lift axis has a corresponding outputsection, and a traverse operably connecting the corresponding outputsection of each of the more than one independent lift axis to the commonoutput so that mixed cases from each independent lift axis reach thecommon output via the traverse.

In accordance with one or more aspects of the disclosed embodiment theordered sequence of mixed cases at the common output is created on thetraverse, and substantially within bounds defined by outermostindependent lift axes of the lifting transport system.

In accordance with one or more aspects of the disclosed embodiment thetraverse operably interconnects at least two of the more than oneindependent lift axis with each other.

In accordance with one or more aspects of the disclosed embodiment thetraverse is configured so as to form an bypass path for mixed casestransported and output by the more than one independent lift axis of thelifting transport system effecting resequencing, at least in part, froman inferior ordered sequence of mixed cases, at infeed of the liftingtransport system, to a superior ordered sequence of mixed cases, atoutput of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment atleast one independent lift axis of the more than one independent liftaxis is configured so as to form an bypass path for mixed casestransported and output by the more than one independent lift axis of thelifting transport system effecting resequencing, at least in part, froman inferior ordered sequence of mixed cases, at infeed of the liftingtransport system, to a superior ordered sequence of mixed cases, atoutput of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis crosses thelift axis from one side to another side on a common level of themulti-level transport system.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases from one side of the lift axis to another sideof the lift axis on the common level.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis crosses thelift axis from one side to another side on different levels of themulti-level transport system.

In accordance with one or more aspects of the disclosed embodiment, thebypass path has a bypass portion extending along the lift axis andbypass portions extending along respective planes of the differentlevels.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases from one side of the lift axis to another sideof the lift axis on the different levels.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis has atleast a bypass portion extending along the lift axis and has bypassportions extending along respective planes of different levels on a sameside of the lift axis.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases between the different levels on the same side ofthe lift axis.

In accordance with one or more aspects of the disclosed embodiment theordered sequence of mixed cases created at and from the common output inaccordance to a predetermined case out ordered sequence of mixed casesis produced substantially continuously and consistent with a high speedpallet builder building at least one mixed case pallet layer of mixedlaterally distributed and stacked mixed cases.

In accordance with one or more aspects of the disclosed embodiment aproduct order fulfillment system comprises:

a multi-level transport system, each level thereof having acorresponding independent asynchronous level transport system, of mixedcases, separate and distinct from the asynchronous level transportsystem corresponding to each other level of the multi-level transportsystem, the asynchronous level transport system defining an array ofasynchronous level transport axes, corresponding to the level, and beingconfigured to hold and asynchronously transport at least one caseproviding transport of mixed cases along the array of asynchronous leveltransport axes;

a lifting transport system with more than one independent lift axis,each of the more than one independent lift axis being configured toindependently hold the at least one case and reciprocate along a lifttravel axis independently raising and lowering the at least one case,the more than one independent lift axis each being communicably coupledto a common lift transport output through which each of the more thanone independent lift axis commonly output the mixed cases from liftingtransport system; and

an infeed interface communicably coupling the multi-level transportsystem with each of the more than one independent lift axis, the infeedinterface comprising different infeed stations distributed at eachasynchronous level transport system for each of the more than oneindependent lift axis so that each of the more than one independent liftaxis has a different corresponding infeed station at each asynchronouslevel transport system through which mixed cases feed from themulti-level transport system to each of the more than one independentlift axis;

wherein the more than one independent lift axis are configured so as tooutput mixed cases substantially continuously through the common lifttransport output in a predetermined case out ordered sequence decoupledfrom an available sequence of mixed cases from and created by themulti-level transport system at the infeed interface and that feed themore than one independent lift axis through the infeed interface.

In accordance with one or more aspects of the disclosed embodiment, themore than one independent lift axis form an array of lift axes arrayedin at least one direction.

In accordance with one or more aspects of the disclosed embodiment, themore than one independent lift axis form an array of lift axes arrayedin more than one direction.

In accordance with one or more aspects of the disclosed embodiment themore than one independent lift axis of the lifting transport systemcreate a lift transport stream of mixed cases from the infeed interface,where the lift transport stream has the available sequence of mixedcases, to the common lift transport output where the lift transportstream has the predetermined case out ordered sequence, and at least onelift axis from the more than one independent lift axis defines a passthrough with respect to another of the more than one independent liftaxis effecting on the fly resequencing from the available sequence ofmixed case in the lift transport stream to the predetermined case outordered sequence of mixed cases at the common lift transport output.

In accordance with one or more aspects of the disclosed embodiment themore than one independent lift axis are configured so as to resequencethe mixed cases and effect a change in the ordered sequence of the mixedcases, with the lifting transport system in motus, from an inferiorordered sequence of mixed cases, at infeed of the lifting transportsystem, to a superior ordered sequence of mixed cases, at output of thelifting transport system, the inferior ordered sequence and superiorordered sequence respectively being of inferior sequencing in sequenceorder and superior sequencing in sequence order relative to thepredetermined case out ordered sequence.

In accordance with one or more aspects of the disclosed embodiment thesuperior ordered sequence is characterized by its sequence order ofmixed cases that converges with the predetermined case out orderedsequence so that there is a strong correlation between respectivesequence orders of the superior ordered sequence and the predeterminedcase out ordered sequence, and wherein the inferior ordered sequence ischaracterized by its sequence order of mixed cases that diverges from oris substantially neutral to the predetermined case out ordered sequenceso that there is a weak correlation between respective sequence ordersof the inferior ordered sequence and the predetermined case out orderedsequence.

In accordance with one or more aspects of the disclosed embodiment thestrong correlation is such that the sequence order is a near netsequence order to that of the predetermined case out ordered sequence ofmixed cases.

In accordance with one or more aspects of the disclosed embodiment eachof the more than one independent lift axis is communicably coupled toeach asynchronous level transport axis of the array of asynchronouslevel transport axes corresponding to each asynchronous level transportsystem.

In accordance with one or more aspects of the disclosed embodiment eachof the more than one independent lift axis has a corresponding outputsection, and a traverse operably connecting the corresponding outputsection of each of the more than one independent lift axis to the commonlift transport output so that mixed cases from each of the more than oneindependent lift axis reach the common lift transport output via thetraverse.

In accordance with one or more aspects of the disclosed embodiment theordered sequence of mixed cases at the common lift transport output iscreated on the traverse, and substantially within bounds defined byoutermost independent lift axes of the lifting transport system.

In accordance with one or more aspects of the disclosed embodiment thetraverse operably interconnects at least two of the more than oneindependent lift axis with each other.

In accordance with one or more aspects of the disclosed embodiment thetraverse is configured so as to form an bypass path for mixed casestransported and output by the more than one independent lift axis of thelifting transport system effecting resequencing, at least in part, froman inferior ordered sequence of mixed cases, at infeed of the liftingtransport system, to a superior ordered sequence of mixed cases, atoutput of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment atleast one independent lift axis of the more than one independent liftaxis is configured so as to form an bypass path for mixed casestransported and output by the more than one independent lift axis of thelifting transport system effecting resequencing, at least in part, froman inferior ordered sequence of mixed cases, at infeed of the liftingtransport system, to a superior ordered sequence of mixed cases, atoutput of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis crosses thelift axis from one side to another side on a common level of themulti-level transport system.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases from one side of the lift axis to another sideof the lift axis on the common level.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis crosses thelift axis from one side to another side on different levels of themulti-level transport system.

In accordance with one or more aspects of the disclosed embodiment, thebypass path has a bypass portion extending along the lift axis andbypass portions extending along respective planes of the differentlevels.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases from one side of the lift axis to another sideof the lift axis on the different levels.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis has atleast a bypass portion extending along the lift axis and has bypassportions extending along respective planes of different levels on a sameside of the lift axis.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps case.

In accordance with one or more aspects of the disclosed embodiment theordered sequence of mixed cases created at and from the common lifttransport output in accordance to a predetermined case out orderedsequence of mixed cases is produced substantially continuously andconsistent with a high speed pallet builder building at least one mixedcase pallet layer of mixed laterally distributed and stacked mixedcases.

In accordance with one or more aspects of the disclosed embodiment aproduct order fulfillment method comprises:

providing a multi-level transport system, each level thereof having acorresponding independent asynchronous level transport system, of mixedcases, separate and distinct from the asynchronous level transportsystem corresponding to each other level of the multi-level transportsystem, the asynchronous level transport system defining an array ofasynchronous level transport axes, corresponding to the level, and beingconfigured to hold and asynchronously transport at least one caseproviding transport of mixed cases along the array of asynchronous leveltransport axes;

providing a lifting transport system with more than one independent liftaxis, each of the more than one independent lift axis being configuredto independently hold the at least one case and reciprocate along a lifttravel axis independently raising and lowering the at least one caseproviding lifting transport of mixed cases between more than one of thelevels of the multi-level transport system, each independent lift axisbeing communicably coupled to each asynchronous level transport systemso as to provide for exchange of the at least one case between eachasynchronous level transport system and each independent lift axis, andmixed cases transferred from at least one asynchronous level transportsystem infeed to each of the more than one independent lift axis so thatmixed cases are output by the independent lift axis from the multi-leveltransport system; and

creating, with the more than one independent lift axis, at and from acommon output, an ordered sequence of mixed cases in accordance to apredetermined case out ordered sequence of mixed cases, wherein eachindependent lift axis, of the more than one lift axis, is communicablycoupled to each other independent lift axis of the more than one liftaxis and forms the common output of mixed cases output by each of themore than one independent lift axis.

In accordance with one or more aspects of the disclosed embodiment, themore than one independent lift axis form an array of lift axes arrayedin at least one direction.

In accordance with one or more aspects of the disclosed embodiment, themore than one independent lift axis form an array of lift axes arrayedin more than one direction.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises resequencing, with the more than oneindependent lift axis, the mixed cases and effecting a change in theordered sequence of the mixed cases, with the lifting transport systemin motus, from an inferior ordered sequence of mixed cases, at infeed ofthe lifting transport system, to a superior ordered sequence of mixedcases, at output of the lifting transport system, the inferior orderedsequence and superior ordered sequence respectively being of inferiorsequencing in sequence order and superior sequencing in sequence orderrelative to the predetermined case out ordered sequence.

In accordance with one or more aspects of the disclosed embodiment thesuperior ordered sequence is characterized by its sequence order ofmixed cases that converges with the predetermined case out orderedsequence so that there is a strong correlation between respectivesequence orders of the superior ordered sequence and the predeterminedcase out ordered sequence, and wherein the inferior ordered sequence ischaracterized by its sequence order of mixed cases that diverges from oris substantially neutral to the predetermined case out ordered sequenceso that there is a weak correlation between respective sequence ordersof the inferior ordered sequence and the predetermined case out orderedsequence.

In accordance with one or more aspects of the disclosed embodiment thestrong correlation is such that the sequence order is a near netsequence order to that of the predetermined case out ordered sequence ofmixed cases.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises communicably coupling each of the more than oneindependent lift axis to each asynchronous level transport axis of thearray of asynchronous level transport axes corresponding to eachasynchronous level transport system.

In accordance with one or more aspects of the disclosed embodiment eachof the more than one independent lift axis has a corresponding outputsection, and a traverse operably connecting the corresponding outputsection of each of the more than one independent lift axis to the commonoutput, the method further comprising transporting the mixed cases withthe traverse so that the mixed cases from each independent lift axisreach the common output via the traverse.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises creating the ordered sequence of mixed cases atthe common output on the traverse, and substantially within boundsdefined by outermost independent lift axes of the lifting transportsystem.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises operably interconnecting, with the traverse, atleast two of the more than one independent lift axis with each other.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises forming a bypass path, with the traverse, formixed cases transported and output by the more than one independent liftaxis of the lifting transport system effecting resequencing, at least inpart, from an inferior ordered sequence of mixed cases, at infeed of thelifting transport system, to a superior ordered sequence of mixed cases,at output of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises forming a bypass path, with at least oneindependent lift axis of the more than one independent lift axis, formixed cases transported and output by the more than one independent liftaxis of the lifting transport system effecting resequencing, at least inpart, from an inferior ordered sequence of mixed cases, at infeed of thelifting transport system, to a superior ordered sequence of mixed cases,at output of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis crosses thelift axis from one side to another side on a common level of themulti-level transport system.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases from one side of the lift axis to another sideof the lift axis on the common level.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis crosses thelift axis from one side to another side on different levels of themulti-level transport system.

In accordance with one or more aspects of the disclosed embodiment, thebypass path has a bypass portion extending along the lift axis andbypass portions extending along respective planes of the differentlevels.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases from one side of the lift axis to another sideof the lift axis on the different levels.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis has atleast a bypass portion extending along the lift axis and has bypassportions extending along respective planes of different levels on a sameside of the lift axis.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps case.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises producing the ordered sequence of mixed casessubstantially continuously and consistent with a high speed palletbuilder building at least one mixed case pallet layer of mixed laterallydistributed and stacked mixed cases, wherein the ordered sequence ofmixed cases is created at and from the common output in accordance to apredetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment aproduct order fulfillment method comprises:

providing a multi-level transport system, each level thereof having acorresponding independent asynchronous level transport system, of mixedcases, separate and distinct from the asynchronous level transportsystem corresponding to each other level of the multi-level transportsystem, the asynchronous level transport system defining an array ofasynchronous level transport axes, corresponding to the level, and beingconfigured to hold and asynchronously transport at least one caseproviding transport of mixed cases along the array of asynchronous leveltransport axes;

providing a lifting transport system with more than one independent liftaxis, each of the more than one independent lift axis being configuredto independently hold the at least one case and reciprocate along a lifttravel axis independently raising and lowering the at least one case,the more than one independent lift axis each being communicably coupledto a common lift transport output through which each of the more thanone independent lift axis commonly output the mixed cases from liftingtransport system;

providing an infeed interface communicably coupling the multi-leveltransport system with each of the more than one independent lift axis,the infeed interface comprising different infeed stations distributed ateach asynchronous level transport system for each of the more than oneindependent lift axis so that each of the more than one independent liftaxis has a different corresponding infeed station at each asynchronouslevel transport system through which mixed cases feed from themulti-level transport system to each of the more than one independentlift axis; and

outputting mixed cases substantially continuously through the commonlift transport output, with the more than one independent lift axis, soas to output the mixed cases in a predetermined case out orderedsequence decoupled from an available sequence of mixed cases from andcreated by the multi-level transport system at the infeed interface andthat feed the more than one independent lift axis through the infeedinterface.

In accordance with one or more aspects of the disclosed embodiment, themore than one independent lift axis form an array of lift axes arrayedin at least one direction.

In accordance with one or more aspects of the disclosed embodiment, themore than one independent lift axis form an array of lift axes arrayedin more than one direction.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises creating, with the more than one independentlift axis of the lifting transport system, a lift transport stream ofmixed cases from the infeed interface, where the lift transport streamhas the available sequence of mixed cases, to the common lift transportoutput where the lift transport stream has the predetermined case outordered sequence, and at least one lift axis from the more than oneindependent lift axis defines a pass through with respect to another ofthe more than one independent lift axis effecting on the flyresequencing from the available sequence of mixed case in the lifttransport stream to the predetermined case out ordered sequence of mixedcases at the common lift transport output.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises resequencing, with the more than oneindependent lift axis, the mixed cases and effecting a change in theordered sequence of the mixed cases, with the lifting transport systemin motus, from an inferior ordered sequence of mixed cases, at infeed ofthe lifting transport system, to a superior ordered sequence of mixedcases, at output of the lifting transport system, the inferior orderedsequence and superior ordered sequence respectively being of inferiorsequencing in sequence order and superior sequencing in sequence orderrelative to the predetermined case out ordered sequence.

In accordance with one or more aspects of the disclosed embodiment thesuperior ordered sequence is characterized by its sequence order ofmixed cases that converges with the predetermined case out orderedsequence so that there is a strong correlation between respectivesequence orders of the superior ordered sequence and the predeterminedcase out ordered sequence, and wherein the inferior ordered sequence ischaracterized by its sequence order of mixed cases that diverges from oris substantially neutral to the predetermined case out ordered sequenceso that there is a weak correlation between respective sequence ordersof the inferior ordered sequence and the predetermined case out orderedsequence.

In accordance with one or more aspects of the disclosed embodiment thestrong correlation is such that the sequence order is a near netsequence order to that of the predetermined case out ordered sequence ofmixed cases.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises communicably coupling each of the more than oneindependent lift axis to each asynchronous level transport axis of thearray of asynchronous level transport axes corresponding to eachasynchronous level transport system.

In accordance with one or more aspects of the disclosed embodiment eachof the more than one independent lift axis has a corresponding outputsection, and a traverse operably connecting the corresponding outputsection of each of the more than one independent lift axis to the commonlift transport output, the method further comprising transporting themixed cases with the traverse so that the mixed cases from each of themore than one independent lift axis reach the common lift transportoutput via the traverse.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises creating the ordered sequence of mixed cases atthe common lift transport output on the traverse, and substantiallywithin bounds defined by outermost independent lift axes of the liftingtransport system.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises operably interconnecting, with the traverse, atleast two of the more than one independent lift axis with each other.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises forming a bypass path, with the traverse formixed cases transported and output by the more than one independent liftaxis of the lifting transport system effecting resequencing, at least inpart, from an inferior ordered sequence of mixed cases, at infeed of thelifting transport system, to a superior ordered sequence of mixed cases,at output of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises forming a bypass path, with at least oneindependent lift axis of the more than one independent lift axis, formixed cases transported and output by the more than one independent liftaxis of the lifting transport system effecting resequencing, at least inpart, from an inferior ordered sequence of mixed cases, at infeed of thelifting transport system, to a superior ordered sequence of mixed cases,at output of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis crosses thelift axis from one side to another side on a common level of themulti-level transport system.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases from one side of the lift axis to another sideof the lift axis on the common level.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis crosses thelift axis from one side to another side on different levels of themulti-level transport system.

In accordance with one or more aspects of the disclosed embodiment, thebypass path has a bypass portion extending along the lift axis andbypass portions extending along respective planes of the differentlevels.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps cases from one side of the lift axis to another sideof the lift axis on the different levels.

In accordance with one or more aspects of the disclosed embodiment, thebypass path formed by the at least one independent lift axis has atleast a bypass portion extending along the lift axis and has bypassportions extending along respective planes of different levels on a sameside of the lift axis.

In accordance with one or more aspects of the disclosed embodiment, thebypass path swaps case.

In accordance with one or more aspects of the disclosed embodiment themethod further comprises producing the ordered sequence of mixed casessubstantially continuously and consistent with a high speed palletbuilder building at least one mixed case pallet layer of mixed laterallydistributed and stacked mixed cases, wherein the ordered sequence ofmixed cases created at and from the common lift transport output inaccordance to a predetermined case out ordered sequence of mixed cases.

It should be understood that the foregoing description is onlyillustrative of the aspects of the disclosed embodiment. Variousalternatives and modifications can be devised by those skilled in theart without departing from the aspects of the disclosed embodiment.Accordingly, the aspects of the disclosed embodiment are intended toembrace all such alternatives, modifications and variances that fallwithin the scope of the appended claims. Further, the mere fact thatdifferent features are recited in mutually different dependent orindependent claims does not indicate that a combination of thesefeatures cannot be advantageously used, such a combination remainingwithin the scope of the aspects of the invention.

What is claimed is:
 1. A method for product order fulfillmentcomprising: providing a multi-level transport system of a product orderfulfillment system, each level thereof having a correspondingindependent asynchronous level transport system, of mixed cases,separate and distinct from the asynchronous level transport systemcorresponding to each other level of the multi-level transport system,the asynchronous level transport system defining an array ofasynchronous level transport axes, corresponding to the level, and beingconfigured to hold and asynchronously transport at least one caseproviding transport of mixed cases along the array of asynchronous leveltransport axes; and providing a lifting transport system with more thanone independent lift axis, each of the more than one independent liftaxis being configured to independently hold the at least one case andreciprocate along a lift travel axis independently raising and loweringthe at least one case providing lifting transport of mixed cases betweenmore than one of the levels of the multi-level transport system, eachindependent lift axis being communicably coupled to each asynchronouslevel transport system; effecting exchanging of the at least one casebetween each asynchronous level transport system and each independentlift axis, and transferring of mixed cases from at least oneasynchronous level transport system infeed to each of the more than oneindependent lift axis so that mixed cases are output by the independentlift axis from the multi-level transport system; wherein eachindependent lift axis, of the more than one lift axis, is communicablycoupled to each other independent lift axis of the more than one liftaxis and forms a common output of mixed cases output by each of the morethan one independent lift axis, and the more than one independent liftaxis are configured so as to create, at and from the common output, anordered sequence of mixed cases in accordance to a predetermined caseout ordered sequence of mixed cases.
 2. The method of claim 1, furthercomprising resequencing, with the more than one independent lift axis,the mixed cases and effecting a change in the ordered sequence of themixed cases, with the lifting transport system in motus, from aninferior ordered sequence of mixed cases, at infeed of the liftingtransport system, to a superior ordered sequence of mixed cases, atoutput of the lifting transport system, the inferior ordered sequenceand superior ordered sequence respectively being of inferior sequencingin sequence order and superior sequencing in sequence order relative tothe predetermined case out ordered sequence.
 3. The method of claim 2,wherein the superior ordered sequence is characterized by its sequenceorder of mixed cases that converges with the predetermined case outordered sequence so that there is a strong correlation betweenrespective sequence orders of the superior ordered sequence and thepredetermined case out ordered sequence, and wherein the inferiorordered sequence is characterized by its sequence order of mixed casesthat diverges from or is substantially neutral to the predetermined caseout ordered sequence so that there is a weak correlation betweenrespective sequence orders of the inferior ordered sequence and thepredetermined case out ordered sequence.
 4. The method of claim 3,wherein the strong correlation is such that the sequence order is a nearnet sequence order to that of the predetermined case out orderedsequence of mixed cases.
 5. The method of claim 1, wherein each of themore than one independent lift axis is communicably coupled to eachasynchronous level transport axis of the array of asynchronous leveltransport axes corresponding to each asynchronous level transportsystem.
 6. The method of claim 1, wherein each of the more than oneindependent lift axis has a corresponding output section, and a traverseoperably connecting the corresponding output section of each of the morethan one independent lift axis to the common output so that mixed casesfrom each independent lift axis reach the common output via thetraverse.
 7. The method of claim 6, further comprising creating theordered sequence of mixed cases at the common output on the traverse,and substantially within bounds defined by outermost independent liftaxes of the lifting transport system.
 8. The method of claim 6, furthercomprising operably interconnecting, with the traverse, at least two ofthe more than one independent lift axis with each other.
 9. The methodof claim 6, further comprising effecting resequencing, at least in part,from an inferior ordered sequence of mixed cases, at infeed of thelifting transport system, to a superior ordered sequence of mixed cases,at output of the lifting transport system, with the traverse forming anbypass path for mixed cases transported and output by the more than oneindependent lift axis of the lifting transport system, wherein theinferior ordered sequence and superior ordered sequence respectivelybeing of inferior sequencing in sequence order and superior sequencingin sequence order relative to the predetermined case out orderedsequence of mixed cases.
 10. The method of claim 1, further comprisingeffecting resequencing, at least in part, from an inferior orderedsequence of mixed cases, at infeed of the lifting transport system, to asuperior ordered sequence of mixed cases, at output of the liftingtransport system, with at least one independent lift axis of the morethan one independent lift axis forming an bypass path for mixed casestransported and output by the more than one independent lift axis of thelifting transport system, wherein the inferior ordered sequence andsuperior ordered sequence respectively being of inferior sequencing insequence order and superior sequencing in sequence order relative to thepredetermined case out ordered sequence of mixed cases.
 11. The methodfor product order fulfillment of claim 1, wherein the ordered sequenceof mixed cases created at and from the common output in accordance to apredetermined case out ordered sequence of mixed cases is producedsubstantially continuously and consistent with a high speed palletbuilder building at least one mixed case pallet layer of mixed laterallydistributed and stacked mixed cases.
 12. A method comprising: providinga multi-level transport system of a product order fulfillment system,each level thereof having a corresponding independent asynchronous leveltransport system, of mixed cases, separate and distinct from theasynchronous level transport system corresponding to each other level ofthe multi-level transport system, the asynchronous level transportsystem defining an array of asynchronous level transport axes,corresponding to the level, and being configured to hold andasynchronously transport at least one case providing transport of mixedcases along the array of asynchronous level transport axes; providing alifting transport system with more than one independent lift axis, eachof the more than one independent lift axis being configured toindependently hold the at least one case and reciprocate along a lifttravel axis independently raising and lowering the at least one case,the more than one independent lift axis each being communicably coupledto a common lift transport output through which each of the more thanone independent lift axis commonly output the mixed cases from liftingtransport system; and providing an infeed interface communicablycoupling the multi-level transport system with each of the more than oneindependent lift axis, the infeed interface comprising different infeedstations distributed at each asynchronous level transport system foreach of the more than one independent lift axis so that each of the morethan one independent lift axis has a different corresponding infeedstation at each asynchronous level transport system through which mixedcases feed from the multi-level transport system to each of the morethan one independent lift axis; effecting output, with the more than oneindependent lift axis, of mixed cases substantially continuously throughthe common lift transport output in a predetermined case out orderedsequence decoupled from an available sequence of mixed cases from andcreated by the multi-level transport system at the infeed interface andthat feed the more than one independent lift axis through the infeedinterface.
 13. The method of claim 12, wherein the more than oneindependent lift axis of the lifting transport system create a lifttransport stream of mixed cases from the infeed interface, where thelift transport stream has the available sequence of mixed cases, to thecommon lift transport output where the lift transport stream has thepredetermined case out ordered sequence, and at least one lift axis fromthe more than one independent lift axis defines a pass through withrespect to another of the more than one independent lift axis, themethod further comprising effecting on the fly resequencing from theavailable sequence of mixed cases in the lift transport stream to thepredetermined case out ordered sequence of mixed cases at the commonlift transport output.
 14. The method of claim 12, further comprisingresequencing, with the more than one independent lift axis, the mixedcases and effecting a change in the ordered sequence of the mixed cases,with the lifting transport system in motus, from an inferior orderedsequence of mixed cases, at infeed of the lifting transport system, to asuperior ordered sequence of mixed cases, at output of the liftingtransport system, the inferior ordered sequence and superior orderedsequence respectively being of inferior sequencing in sequence order andsuperior sequencing in sequence order relative to the predetermined caseout ordered sequence.
 15. The method of claim 14, wherein the superiorordered sequence is characterized by its sequence order of mixed casesthat converges with the predetermined case out ordered sequence so thatthere is a strong correlation between respective sequence orders of thesuperior ordered sequence and the predetermined case out orderedsequence, and wherein the inferior ordered sequence is characterized byits sequence order of mixed cases that diverges from or is substantiallyneutral to the predetermined case out ordered sequence so that there isa weak correlation between respective sequence orders of the inferiorordered sequence and the predetermined case out ordered sequence. 16.The method of claim 15, wherein the strong correlation is such that thesequence order is a near net sequence order to that of the predeterminedcase out ordered sequence of mixed cases.
 17. The method of claim 12,wherein each of the more than one independent lift axis is communicablycoupled to each asynchronous level transport axis of the array ofasynchronous level transport axes corresponding to each asynchronouslevel transport system.
 18. The method of claim 12, wherein each of themore than one independent lift axis has a corresponding output section,and a traverse operably connecting the corresponding output section ofeach of the more than one independent lift axis to the common lifttransport output so that mixed cases from each of the more than oneindependent lift axis reach the common lift transport output via thetraverse.
 19. The method of claim 18, further comprising creating, onthe traverse, the ordered sequence of mixed cases at the common lifttransport output, and substantially within bounds defined by outermostindependent lift axes of the lifting transport system.
 20. The method ofclaim 18, further comprising operably interconnecting, with thetraverse, at least two of the more than one independent lift axis witheach other.
 21. The method of claim 18, further comprising effectingresequencing, at least in part, from an inferior ordered sequence ofmixed cases, at infeed of the lifting transport system, to a superiorordered sequence of mixed cases, at output of the lifting transportsystem, the traverse forming a bypass path for mixed cases transportedand output by the more than one independent lift axis of the liftingtransport system, wherein the inferior ordered sequence and superiorordered sequence respectively being of inferior sequencing in sequenceorder and superior sequencing in sequence order relative to thepredetermined case out ordered sequence of mixed cases.
 22. The methodof claim 12, further comprising effecting resequencing, at least inpart, from an inferior ordered sequence of mixed cases, at infeed of thelifting transport system, to a superior ordered sequence of mixed cases,at output of the lifting transport system, the at least one independentlift axis of the more than one independent lift axis forming a bypasspath for mixed cases transported and output by the more than oneindependent lift axis of the lifting transport system, wherein theinferior ordered sequence and superior ordered sequence respectivelybeing of inferior sequencing in sequence order and superior sequencingin sequence order relative to the predetermined case out orderedsequence of mixed cases.
 23. The method of claim 12, wherein the orderedsequence of mixed cases created at and from the common lift transportoutput in accordance to a predetermined case out ordered sequence ofmixed cases is produced substantially continuously and consistent with ahigh speed pallet builder building at least one mixed case pallet layerof mixed laterally distributed and stacked mixed cases.